Reinforced plastic foam cup, method of and apparatus for manufacturing same

ABSTRACT

A reinforced plastic foam cup including a body which defines an open top end and a closed bottom end, wherein the top end has a greater diameter than the bottom end. The body includes a reinforced tapered side wall that extends from the bottom end to the top end. A substantial portion of the reinforced tapered side wall includes a plastic foam layer, a pressure sensitive adhesive layer and a rigid material layer. Such reinforced plastic foam cup provides an improved tactile feel and enhanced insulation and rigidity properties.

PRIORITY CLAIM

This application is continuation-in-part application of, claims priorityto and the benefit of U.S. patent application Ser. No. 11/305,809, filedon Dec. 15, 2005, which is a non-provisional application of, claimspriority to and the benefit of U.S. Provisional Patent Application Ser.No. 60/685,192, filed on May 27, 2005, the entire contents of which areincorporated herein.

CROSS REFERENCE TO RELATED APPLICATIONS

This application relates to the following co-pending, commonly ownedapplications: “REINFORCED PLASTIC FOAM CUP, METHOD OF AND APPARATUS FORMANUFACTURING SAME,” Ser. No. 11/305,785, Attorney Docket No.110047-032; “REINFORCED PLASTIC FOAM CUP, METHOD OF AND APPARATUS FORMANUFACTURING SAME,” Ser. No. 11/305,619, Attorney Docket No.110047-033; “REINFORCED PLASTIC FOAM CUP, METHOD OF AND APPARATUS FORMANUFACTURING SAME,” Ser. No. 11/305,618, Attorney Docket No.110047-037; and “REINFORCED PLASTIC FOAM CUP, METHOD OF AND APPARATUSFOR MANUFACTURING SAME,” Ser. No. 11/305,617, Attorney Docket No.110047-038.

BACKGROUND

Drinking cups are commonly used in the consumption of beverages andother products. Every day, millions of such cups are distributed by fastfood restaurants, coffee shops and convenience stores for single usepurposes. These cups are usually disposed of after a single use.

One type of known disposable cup is a conventional plastic foam cup,such as a beaded polystyrene foam cup. A conventional plastic foam cup,generally illustrated in FIGS. 1 and 2, is generally indicated bynumeral 10. The conventional plastic foam cup 10 includes a resilient,frustoconical body 12. The body is open at a first or top end 14 andclosed at a second or bottom end 16. The top end has a greater diameterthan the bottom end. The frustoconical body is designed to facilitatestacking a plurality of cups together for transportation and dispensingpurposes. The body includes a tapered side wall 18 having an inner faceor surface 20 and an outer face or surface 22 that extends from the topend to the bottom end. The inner face or surface of the tapered sidewall may include at least one interior shelf which facilitates stackingof a plurality of the cups. When the cup is positioned in an uprightposition, the tapered side wall 18 is typically angled offset from avertical plane at a suitable angle in the range of two degrees tofifteen degrees. The tapered side wall 18 includes an outwardly formedor extending lip 24. The outwardly formed lip is suitably shaped suchthat an annular mounting portion of a drinking cup lid (not shown) canbe attached to the formed lip to secure the drinking cup lid to the topof the cup. The outwardly formed lip is sometimes utilized to hold thecup in place prior to the cup being dispensed from a conventional cupdispenser.

One method of forming these conventional plastic foam cups includesadding expanded polystyrene beads (which were previously modified with asuitable foaming agent) into a mold or cavity. Steam is injected intothe mold or cavity which causes the polystyrene beads to expand to formthe cup. The formed cup is subsequently removed from the mold or cavity.However, it should be appreciated that other suitable methods of forminga conventional plastic foam cup, including any suitable injectionmolding technique, are known.

It should be appreciated that it is well known that during an initialperiod of time after molding the cup, the dimensions of the formed cupwill shrink as the polystyrene of the formed cup settles to itspermanent size. That is, after being expanded and molded to form thecup, the expanded polystyrene shrinks or settles until reaching apermanent shrunken state. For example, the upper diameter of a formedtwelve, sixteen or twenty ounce cup will shrink between approximatelythirty and thirty-five thousandths of an inch. Accordingly, afterremoving the formed cup from the mold or cavity, the formed cup must beplaced in a storage facility to allow adequate time for the formed cupto settle until it is further processed. Such storage requirements areassociated with increased costs as cup manufacturers must maintaincostly storage facilities to store these newly formed cups before thecups are ready to be further processed and distributed. Accordingly, aneed exists for an apparatus and method of reinforcing a newly formedplastic foam cup which eliminates the associated storage costs ofwaiting for the expanded polystyrene beads of the newly formed plasticfoam cup to settle.

Conventional plastic foam cups have outstanding heat-insulatingproperties which make them particularly useful for serving hotbeverages, such as coffee, hot tea, soups and hot chocolate. These cupsenable a person to hold the cup without burning themselves and also tendto keep the beverage hot. Conventional plastic foam cups also haveoutstanding cold-insulating properties which make them particularlyuseful for serving cold food or beverages, such as milk shakes, icecream and chilled beverages. These cups tend to keep the food orbeverage cold for extended periods of time. Such conventional plasticfoam cups cost relatively less to manufacture than paper or plasticbased cups and are more leak resistant than cups which are formed frommore than one member as described below. However, the outer surfaces ofconventional plastic foam cups do not provide the tactile feel ofpaper-based cups nor do such cups facilitate high-quality graphics to beprinted on the outer surfaces of such plastic foam cups

Other known insulated disposable cups for hot or cold beverages areformed from paper. Paper cups are fabricated from a paper body memberwhich is bonded to a bottom paper panel member having an upper surfaceand a bottom surface, wherein the joined portions of the bottom panelmember and body member form a seal. Paper-based cups include an innerlining which covers the inner surface of the body and the upper surfaceof the bottom end, wherein the inner lining is effective to preventpenetration of liquid into the paper during use. However, because thesecups are formed from two members (i.e., the body member and the bottompanel member), these cups are more prone to leaking along the seam wherethe two members are joined. Conventional paper cups have an outersurface which provides a comfortable tactile feel but have very poorheat-insulating qualities. For example, paper cups are often too hot tohandle for a period of time after being filled with a hot beverage.Beverage servers and consumers commonly nest two or more paper-basedcups together or add an insulating sleeve to provide insulation for hotdrinks such as hot coffee, hot tea and hot chocolate. This isundesirable because it increases the number of cups or sleeves used andcosts additional money. Double cupping can also make a filled cup moreunstable or tipsy.

To solve these problems, it has been proposed to attach paper to aplastic foam cup. One known method of applying paper to a plastic foamcup is to spot glue portions of the inner face of a stationary piece ofpaper with a suitable adhesive and bringing a cup in contact with thestationary paper to attach the paper to the plastic foam cup. Thisresults in substantial portions of the paper not including adhesive. Dueto the inconsistent and incomplete placement of the adhesive on thepaper, wrinkles are formed when the paper is applied to or otherwisewrapped around the cup. Such wrinkles are undesirable for a manufacturerand aesthetically displeasing to consumers.

Another known method includes applying a film to a plastic foam cup andheat shrinking the film on the cup when the cup is formed. Such“in-mold” method includes integrating the film with the material of thecup during the cup manufacturing process. Such integration includesstretching the film around the material which will form the cup andsubsequently heating the material and film to shrink the film to adhereto the material. While this cup includes the desired insulationproperties of a plastic foam cup, this method is relatively expensive.

Accordingly, a need exists to provide a disposable drinking cup with theinsulation properties of a plastic foam cup and the tactile feel andhigh quality graphic printing properties of a paper-based cup to providean enhanced drinking experience for a person. Furthermore, a need existsto provide an apparatus, system and method for manufacturing such adisposable drinking cup.

The various known machines, systems and methods for affixing one or morelabels to beverage containers do not solve these needs. For instance,U.S. Pat. Nos. 4,709,800; 4,729,81; 4,731,147; 4,743,469; 4,911,285;4,944,825; 4,944,830; 4,950,350; 4,973,374; 4,981,547; 4,994,135;5,004,518; 5,017,261; 5,021,116; 5,037,499; 5,062,917; 5,062,918;5,078,826; 5,082,520; 5,087,317; 5,110,402; 5,120,392; 5,121,827;5,129,984; 5,160,570; 5,167,755; 5,174,851; 5,185,053; 5,188,696;5,201,984; 5,217,538; 5,227,005; 5,271,783; 5,569,353; 5,713,403;5,882,474; and 6,050,319 describe known machines, systems and componentsfor applying one or more labels to beverage containers. These patents donot provide solutions to the above mentioned problems The reinforced cupand the cup reinforcing machines, apparatus, systems and methodsdisclosed herein represent, at least in part, improvements of one ormore of the machines, systems and methods disclosed in such patents.

SUMMARY

The present disclosure relates in general to a reinforced plastic foamcup, and more particularly to a disposable plastic foam cup with anattached reinforcing member and to apparatus, methods and supplies formanufacturing the same.

Generally, in one embodiment, the reinforced plastic foam cup includes areinforcing member attached to a substantial portion of the outersurface of the tapered side wall of the body of the reinforced plasticfoam cup. The substantial portion of the tapered side wall which thereinforcing member is attached to will thus include a plastic foamlayer, an adhesive layer and a rigid material layer. Compared to anon-reinforced plastic foam cup which only includes a plastic foamlayer, the reinforced plastic foam cup with a multi-layered tapered sidewall (i.e., the three layers of the plastic foam layer, the adhesivelayer and the rigid material layer) provides a substantial increase inthe rigidity of the reinforced plastic foam cup. Accordingly, thereinforced plastic foam cup provides the insulation properties of aplastic foam cup and the tactile feel of a paper-based cup.

In one embodiment, the base cup (i.e., the pre-reinforced plastic foamcup) is a conventional plastic foam cup, such as a cup formed frombeaded polystyrene or any other suitable material. More specifically,the base or pre-reinforced plastic foam cup includes a resilient,frustoconical body. The body is open at a first or top end and closed ata second or bottom end. The top end has a greater diameter than thebottom end. The body includes a tapered side wall having an inner faceor surface and an outer face or surface. The tapered side wall extendsfrom the bottom end of the body to the top end of the body at a suitableangle offset from a vertical plane. The cup also includes an outwardlyformed lip extending from the tapered side wall. The outwardly formedlip is suitably shaped such that the annular mounting portion of anappropriately shaped and sized drinking cup lid may be attached to theformed lip to secure the drinking cup lid to the top of the base cup. Inone alternative embodiment as further described below, the conventionalplastic foam cup has been modified to be handled by the cup reinforcingsystem described below. These modifications generally include:increasing the height of side wall below the bottom wall of the cup,increasing the angle of the inner surface of the tapered side wall ofthe cup below and adjacent to the bottom wall, and increasing the widthof the outwardly extending lip at the top end of the cup.

In one embodiment, a reinforcing member or reinforcer includes a bodyformed from a malleable, flexible material, such as a suitable paper, asuitable plastic, a suitable composite material or any other suitablematerial. While this material is flexible, it has properties whichprovide rigidity and durability when attached to the base cup. Thus, itis sometimes referred to herein as a rigid material. In one embodiment,the body is defined by an annular, concavely shaped top edge, anannular, convexly shaped bottom edge, an angled front or leading edgeand an angled rear or trailing edge. In one embodiment, for reasonsdescribed below, a portion of the front or leading edge is vertically orsubstantially vertically disposed. In this embodiment, the vertical orsubstantially vertical portion of the front edge is clearlydistinguishable from the remainder of the front edge of the reinforcingmember and the rear edge of the reinforcing member which are eachrespectively angled offset from a vertical plane. It should beappreciated that the angling of a substantial portion of the front edgeand the entire rear edge of the reinforcing member provides an enhancedfit of the reinforcing member when attached to the outer surface of thetapered side wall of the base cup. In another embodiment, as furtherdescribed below, a portion of the trailing edge is vertically orsubstantially vertically disposed. In this embodiment, the verticalportion of the trailing edge is clearly distinguished from the remainderof the trailing or rear edge of the reinforcing member.

In one embodiment, an inner face or surface of the body of thereinforcing member is completely or substantially completely coated witha pressure sensitive adhesive. That is, the entire or substantially theentire inner surface is coated with a pressure sensitive adhesive. Anouter face of the body of the reinforcing member may be blank or mayinclude high quality visual content, such as graphics, text and/orimages printed or otherwise formed thereon. As described in the processbelow, in one embodiment, the inner face of the reinforcing member isapplied to and adheres to (by way of the adhesive) all or a substantialportion of the outer surface of the tapered side wall of the base cup.The base cup coupled with the adhered to reinforcing member form areinforced plastic foam cup. The reinforced plastic foam cup with amulti-layered tapered side wall provides a substantial increase in therigidity over a conventional plastic foam cup and over a conventionalcup with paper attached by spot gluing methods. The reinforced plasticfoam cup further provides a suitable branding area where high qualitygraphics, such as a company's logo or suitable marketing indicia, may beprinted and subsequently viewed by a person. It should be appreciatedthat since the inner surface of the reinforcing member is completely orsubstantially completely covered or coated with the pressure sensitiveadhesive in the preferred embodiment, the entire reinforcing member willadhere to the tapered side wall of the base cup, thus avoiding theformation of wrinkles in the reinforcing member, adding strength orstiffness to the base cup and adding a tactile feel to the entire orsubstantially the entire outer surface of the base cup. In oneembodiment, as described below, the reinforcing member is attached tothe based cup in an overlapping manner.

In one embodiment, the method or process of manufacturing theabove-described reinforced plastic foam cup generally includesdetermining a center point of the top edge and bottom edge of thereinforcing member, wherein the center point corresponds with the troughof the concavely shaped top edge of the reinforcing member and also theapex of the convexly shaped bottom edge of the reinforcing member. Themethod includes positioning a base or pre-reinforced plastic foam cup inan upside-down position and also positioning the reinforcing memberadjacent to the cup at an angle (offset from a vertical plane) whichcorresponds with the angle (offset from a vertical plane) of the taperedside wall of the base or pre-reinforced plastic foam cup. This is doneas the cup moves on a cup conveyer system and the reinforcing membermoves or is dispensed by a dispenser. The method includes initiallyattaching the moving reinforcing member to the tapered side wall of themoving cup along a vertical axis which runs through the determinedcenter point of the top edge and bottom edge of the reinforcing member.In one embodiment, the method includes sequentially attaching a firstremaining unattached portion of the reinforcing member (i.e., theportion extending from the center vertical axis to the trailing edge)and a second remaining unattached portion of the reinforcing member(i.e., the portion extending from center vertical axis to the leadingedge) to the tapered side wall of the cup to form the reinforced plasticfoam cup.

More specifically, in one embodiment, the method of manufacturing thereinforced plastic foam cup includes placing a base cup (i.e., apre-reinforced plastic foam cup) face down or resting on the open topend on a cup conveyer system of a cup reinforcing system or apparatus.The method includes supplying and dispensing reinforcing members from areinforcing member dispenser. In one embodiment, the reinforcing memberdispenser feeds the reinforcing member until the cup reinforcing systemdetermines that a vertical axis which runs through a center point of thetop edge and bottom edge of the reinforcing member is aligned with thetapered side wall of the base cup. In this embodiment, due to theangling of the tapered side wall of the cup and the relatively planarreinforcing member, the release liner (on which the reinforcing memberis releasably attached to) is positioned at a suitable angle whichcorresponds with the angle of the tapered side wall of the base cup andthus when the reinforcing member is separated from the release liner,the reinforcing member is positioned at a suitable angle whichcorresponds with the angle of the tapered side wall of the base cup.

In one embodiment, a sensor of the cup reinforcing system determines thelocation or position of the reinforcing member as the reinforcing memberdispenser feeds the reinforcing member through the cup reinforcingsystem. Based on this determined position of the reinforcing member (andother suitable information such as the speed which the reinforcingmember dispenser is feeding the reinforcing member), a processor of thecup reinforcing system, such as a microprocessor, amicrocontroller-based platform, a suitable integrated circuit or one ormore application-specific integrated circuits (ASIC's), determines orcalculates when the reinforcing member is moved into a position in whichthe centered vertical axis of the reinforcing member is aligned with thetapered side wall of the base cup. The sensor detects the location ofthe substantially vertical portion of the front or leading edge of thereinforcing member to determine the relative position of the reinforcingmember. In one embodiment, the sensor is positioned such that the sensordetects the exact location of each reinforcing member immediately priorto that reinforcing member being affixed to a base cup. In thisembodiment, positioning the sensor at such a position provides forsubstantially increased accuracy in the placement of the reinforcingmember on the base cup which, as described in more detail below,provides for a proper engagement between the reinforcing member and thecup. In alternative embodiments, any suitable timing mechanism may beused to accomplish this alignment process. It should be appreciated thatany suitable mechanism or indicator, whether attached to or printed onthe reinforcing member, may be utilized to locate the centered verticalaxis of the reinforcing member. In different embodiments, suchmechanisms include any suitable notch, notches, mark or markings on thereinforcing member, any suitable radio-frequency identificationindicator, any suitable visible indicator (such as a barcode) or anysuitable invisible or not readily visible indicator.

At the point in the process when the centered vertical axis of thereinforcing member is aligned with the wall of the base cup, the innerface of the reinforcing member (which is completely or substantiallycompletely coated with a pressure sensitive adhesive) is initiallyattached to the cup along the centered vertical axis. As describedabove, the reinforcing member is situated at an angle which correspondswith the angle of the tapered side wall of the base cup and thus thereinforcing member is attached to the base cup at an angle whichcorresponds with the angle of the tapered side wall of the base cup. Itshould be appreciated that after the reinforcing member is initiallyattached to the cup along the centered vertical axis, the leading andtrailing edges of the cup remain unattached or are otherwise free.

After the centered vertical axis of the reinforcing member is attachedto the cup, the cup and the attached reinforcing member continue alongthe cup conveyer system and the remainder of the reinforcing member isattached to the wall of the base cup. In one embodiment, the cup isrotated in a first direction to attach a first remaining portion of thereinforcing member (i.e., the portion extending from the centeredvertical axis to the trailing edge) to the cup. Subsequently, the cup isrotated in a second, opposite direction to attach a second remainingportion of the reinforcing member (i.e., the portion extending from thecentered vertical axis to the leading edge) to the cup. Such a processresults in a reinforced plastic foam cup with substantially increasedrigidity properties when compared to a non-reinforced plastic foam cup.Such a process of attaching the reinforcing member along the centeredvertical axis of the reinforcing member mathematically reduces thelikelihood of error than if the reinforcing member was first attached tothe cup along a non-centered vertical axis. It should be appreciatedthat, as discussed below, other suitable rotation patterns may beemployed in accordance with the cup reinforcing system disclosed herein.

In one alternative embodiment, the cup reinforcing system or apparatusdisclosed herein reinforces a newly formed cup prior to the settling orshrinkage of the expanded polystyrene of the newly formed cup. That is,rather than utilizing a cup which has been previously stored for anadequate amount of time to settle (i.e., shrink to its permanent size),a reinforcing member is applied to a newly formed cup prior to the cupshrinking. In one such embodiment, the length of the reinforcing memberis modified such that when the reinforcing member is applied to the cup,a gap exists between the leading edge of the reinforcing member and thetrailing end of the reinforcing member. In this embodiment, as thedimensions of the cup shrinks to its permanent size, the gap between theleading edge of the reinforcing member and the trailing end of thereinforcing member closes. Accordingly, this embodiment provides a cupreinforcing system or apparatus which utilizes newly formed cups andsubstantially eliminates the overhead costs otherwise associated withstoring newly formed cups until they settle and are ready to beprocessed.

In one embodiment, the cup reinforcing system or apparatus includes acup conveyor system and one or more reinforcing member dispensers. Thecup conveyor system is configured to receive each pre-reinforced cup,transport and space each of such received cups into an appropriateposition for attachment of a reinforcing member and remove each cup fromthe cup reinforcing system after the attachment of a reinforcing memberto that cup. Each reinforcing member dispenser is configured totransport the reinforcing members into the appropriate positions forattachment with the transported cups and thus to attach each reinforcingmember, along a centered vertical axis of the reinforcing member, to thewall of one of the cups at an angle which corresponds with the angle ofthe tapered side wall of the cup.

More specifically, one embodiment of the cup conveyor system generallyincludes a cup dispenser, a cup feeder, a cup spacer, a cup mover, and acup remover. As described in more detail below, a pre-reinforced or basecup enters the cup reinforcing system via the cup dispenser whichdispenses cups, one at a time, from a supply of nested cups. The cuptravels via the cup feeder to the cup spacer, which properly spaces thecups at pre-determined distances apart, and then to the cup mover. Thecup mover moves each cup into the appropriate alignment with thereinforcing member dispenser. A reinforcing member is attached oraffixed to the cup, along its centered vertical axis, by the reinforcingmember dispenser. After the reinforcing member is attached to the cup atthe centered vertical axis, the cup mover rotates the cup to attach theleading and trailing edges of the reinforcing member to the rest of thecup. The reinforced cup is then removed from the cup reinforcing systemvia the cup remover. It should be appreciated that any suitable cupconveyor system and any suitable reinforcing member dispenser whichattaches a reinforcing member to the tapered side wall of a base cupalong the centered vertical axis of the reinforcing member andsubsequently attaches the remaining portions of the reinforcing memberto the tapered side wall of the base cup may be implemented inaccordance with the cup reinforcing system disclosed herein.

In one embodiment, a base cup enters the cup reinforcing system via adual cup dispenser. The dual cup dispenser includes a frame whichsupports at least two guide members which are each configured to hold astack of nested base cups from a suitable supply. Each guide member isassociated with a plurality of threaded cup dispensing screws. Inoperation, the plurality of threaded cup dispensing screws rotate toengage the lips of the nested base cups to separate the base cups, oneat a time, from their respective nested stack. The separated base cupsfall, face down, from the cup dispenser onto the cup feeder.

The cup feeder includes a frame which supports a plurality of adjacentlyarranged movable conveyor belts. In one embodiment, the conveyor beltsdirectly below the guide members of the cup dispenser each define aplurality of apertures or holes. In another embodiment, in addition tothe conveyor belts directly below the guide members of the cup dispenserdefining a plurality of apertures or holes, one or more of the conveyorbelts not directly below the guide members of the cup dispenser alsoeach define a plurality of apertures or holes. The cup feeder issuitably connected to a vacuum or negative pressure source which causesair to flow from an area above the conveyor belts, through the holes inthe conveyor belts to the vacuum or negative pressure source connectedto the frame of the cup feeder. Such air flow causes each separated basecup to be pulled downwardly by the vacuum or negative pressure, in aface down position, from the cup dispenser onto the cup feeder. Itshould be appreciated that providing vacuum or negative pressure on therelatively light-weight base cups prevents the base cups from tippingover when they are de-nested and dropped from the cup dispenser the cupfeeder.

The base cup travels, via the conveyor belts of the cup feeder, to a cupspacer. The cup spacer includes a frame which supports an in-feed screwor spacer screw and at least one in-feed star-wheel which each define aplurality of spaced apart cup pockets. The spacer screw sequentiallyseparates and spaces the base cups from the cup feeder fortransportation to the in-feed star-wheel(s). The spaced-apart cuppockets of the in-feed star-wheel(s) hold and maintain the spacing ofthe base cups as they are transported to a cup mover or turntable.

The cup mover or turntable includes a plurality of cup holding stationsspaced-apart around the circumference of the turntable. Each individualcup holding station is configured to receive a base cup from an in-feedstar-wheel of the cup spacer and to be able to rotate the base cup afull 360 degrees. After a base cup is positioned on a cup holdingstation of the turntable by the in-feed star wheel of the cup spacer, aspring biased centering bell supported by a rotatable superstructureengages the bottom of the upside down cup to hold the cup in place onthe holding station.

In one embodiment, the cup mover aligns the base cup into an appropriatealignment with a reinforcing member dispenser and the reinforcing memberis attached or affixed to the cup. In one embodiment, each reinforcingmember dispenser includes one or more reinforcing member supply rollholders configured to hold a supply roll of reinforcing members whichinclude a plurality of reinforcers sequentially releasably attached toan elongated release liner. The reinforcing member dispenser includes atleast one and preferably a plurality of drive rollers configured todrive or pull the release liner. The reinforcing member dispenser alsoincludes at least one and preferably a plurality of guides andtensioners, such as guide rollers, configured to guide and maintainsuitable amounts of tension on the release liner. The reinforcing memberdispenser includes a release liner slack accumulator configured toprovide a designated area where slack in the release liner accumulatesto facilitate the alignment of each reinforcing member to each cup andat least one sensor for determining the exact location of eachreinforcing member immediately prior to that reinforcing member beingattached to a cup. The reinforcing member dispenser also includes arelease liner separator for separating the reinforcing members from therelease liner and a release liner accumulation roller configured to holdthe release liner after separation from the reinforcing members.

In one embodiment, the release liner slack accumulator is an elongatedsubstantially unshaped member which provides a designated area whereinslack in the release liner may accumulate. In this embodiment, due tothe need to accurately apply the reinforcing members to the tapered sidewall of the cup along the centered vertical axis of the reinforcingmember, the processor of the cup reinforcing system must often adjustthe speed which the reinforcing members are moving immediately prior toattachment to insure that the cups moving on the turntable and thereinforcing members dispensed by the reinforcing dispenser come intocontact at the appropriate time and location such that the centeredvertical axis of each reinforcing member is applied to each cup on aconstant basis with a margin of error of less than plus or minus 0.1inches. In other words, providing an area where slack can accumulateenables the processor of the cup reinforcing system to adjust the speedat which the liner (and thus the reinforcing members) is fed through thereinforcing member dispenser without otherwise affecting the feed of therelease liner from the supply of release liner. This configurationaccordingly facilitates the exact positioning of each and everyreinforcing member.

In one embodiment, after the base cup is reinforced by the reinforcingmember, the reinforced cup is removed from the cup reinforcing systemvia a cup remover. The cup remover includes one or more out-feedstar-wheels which transport the reinforced cup to an out-feed reinforcedup conveyor apparatus. The out-feed reinforced cup conveyor apparatustransports each of the reinforced cup to a cup positioner, such as a cuptipper, which positions or tips the reinforced cup onto its side(downside leading). The tipped cup is then vacuum pulled via a cupexhaust system to a stack of nested reinforced cups. It should beappreciated that any suitable apparatus for removing the cup may beimplemented in accordance with the cup reinforcing system disclosedherein.

It is therefore an advantage of the present apparatus and method toprovide a disposable plastic foam drinking cup with a substantiallyimproved tactile feel, substantially increased rigidity, andsubstantially increased durability due to a completely affixedreinforcing member.

A further advantage of the present apparatus and method is to provide adisposable plastic foam drinking cup with high quality graphics printedon the outside wall of the cup to enhance the drinking experience for aperson.

A further advantage of the present apparatus and method is to provide adisposable plastic foam drinking cup with a wrinkle-free reinforcingmember that is relatively inexpensive to manufacture.

Additional features and advantages are described in, and will beapparent from, the following Detailed Description and the figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front perspective view of a conventional plastic foam cup.

FIG. 2 is a cross-sectional side view of the conventional plastic foamcup of FIG. 1.

FIG. 3 is a front perspective view of one embodiment of a reinforcedplastic foam cup disclosed herein.

FIG. 3A is a front perspective view of an alternative embodiment of areinforced plastic foam cup disclosed herein.

FIG. 4 is a cross-sectional side view of the reinforced plastic foam cupof FIG. 3.

FIG. 4A is an exploded top plan view of the reinforced plastic foam cupof FIG. 3A during a first time period.

FIG. 4B is an exploded top plan view of the reinforced plastic foam cupof FIG. 3C during a second time period.

FIG. 4C is an exploded top plan view of the reinforced plastic foam cupof FIG. 3A during a third time period.

FIG. 5 is a top plan view of the outside face of one embodiment of areinforcing member disclosed herein.

FIG. 6 is a bottom plan view of the inside face of the reinforcingmember of FIG. 5.

FIG. 7 is a top plan view of a plurality of reinforcing memberssequentially positioned on an elongated release liner.

FIG. 5A is a top plan view of the outside face of an alternativeembodiment of a reinforcing member disclosed herein.

FIG. 6A is a bottom plan view of the inside face of the reinforcingmember of FIG. 5A.

FIG. 7A is a top plan view of a plurality of reinforcing members of FIG.5A sequentially positioned on an elongated release liner.

FIG. 5B is a top plan view of the outside face of another alternativeembodiment of a reinforcing member disclosed herein.

FIG. 8 is a schematic block diagram illustrating one embodiment of amethod of manufacturing the reinforced plastic foam cup of FIG. 3disclosed herein.

FIG. 9 is a diagrammatic top plan view of one embodiment of a cupreinforcing system disclosed herein, illustrating a pre-reinforcedplastic foam cup separate from a reinforcing member.

FIG. 10 is a diagrammatic top plan view of the cup reinforcing system ofFIG. 9, illustrating the pre-reinforced plastic foam cup and thereinforcing member moving into an engagement position.

FIG. 11 is a cross-sectional side view of the separated pre-reinforcedplastic foam cup and reinforcing member of FIG. 10.

FIG. 12 is a diagrammatic top plan view of the cup reinforcing system ofFIG. 9, illustrating a centered vertical axis of the reinforcing memberaligned with the tapered side wall of the pre-reinforced plastic foamcup.

FIG. 13 is a side view of the pre-reinforced plastic foam cup alignedwith the centered vertical axis of the reinforcing member.

FIG. 14 is a cross-sectional side view of the reinforcing memberengaging the tapered side wall of the plastic foam cup.

FIG. 15 is a diagrammatic top plan view of the cup reinforcing system ofFIG. 9, illustrating a first portion of the reinforcing member attachedto the cup and a second portion of the reinforcing member not attachedto the plastic foam cup.

FIG. 16 is a side view of the partially attached reinforcing member ofFIG. 15.

FIG. 17 is a diagrammatic top plan view of the cup reinforcing system ofFIG. 9, illustrating the reinforcing member full attached to the plasticfoam cup to form the reinforced plastic foam cup of FIG. 3.

FIG. 18A is a diagrammatic top plan view of one embodiment of the cupreinforcing system disclosed herein.

FIG. 18B is a diagrammatic side view of the cup reinforcing system ofFIG. 18A.

FIG. 19 is a side view of the dual cup dispenser, the cup conveyor andthe vacuum chamber of one embodiment of the cup reinforcing systemdisclosed herein.

FIG. 20 is a front perspective view of one set of cup dispensing screwsof the dual cup dispenser of FIG. 19.

FIG. 21 is a top plan view of a set of cup dispensing screws of the dualcup dispenser engaging a cup.

FIG. 22 is a front perspective view of the dual cup dispenser, the cupconveyor, the vacuum chamber and the spacing screw of one embodiment ofthe cup reinforcing system disclosed herein.

FIG. 23 is a partially cross-sectional perspective view of the vacuumchamber of FIG. 22, illustrating the plurality of adjacent conveyorbelts and the plurality of air inlets.

FIG. 24A is a schematic side view of the vacuum box of FIG. 22,illustrating the flow of air from an area above the plurality ofconveyor belts, entering the vacuum chamber via the plurality of airinlets and exiting the vacuum chamber via the air outlet.

FIG. 24B is a schematic side view of an alternative embodiment of avacuum box, illustrating the flow of air from an area above theplurality of conveyor belts, entering the vacuum chamber via theplurality of air inlets and exiting the vacuum chamber via a pluralityof air outlets.

FIG. 24C is a schematic side view of an alternative embodiment of avacuum box, illustrating the flow of air from an area above theplurality of conveyor belts, entering a plurality of air flow membersvia the plurality of air inlets and exiting the air flow members via aplurality of air outlets.

FIG. 25 is a side view of the spacing screw, the in-feed star wheels anda portion of the cup mover of one embodiment of the cup reinforcingsystem disclosed herein.

FIG. 26 is a front perspective view of one embodiment of a portion ofthe cup feeder, the spacing screw and a portion of an in-feed star wheelof one embodiment of the cup reinforcing system disclosed herein.

FIG. 27A is a top plan view of one embodiment of a portion of the cupfeeder, the cup spacer illustrating the spacing screw and a pluralityin-feed star-wheels and a portion of the cup mover.

FIG. 27B is a top plan view of an alternative embodiment of a portion ofthe cup feeder, the cup spacer illustrating the spacing screw and onein-feed star-wheel and a portion of the cup mover.

FIG. 28 is a front perspective view of the portion of the cup feeder,the cup spacer illustrating the spacing screw and the plurality in-feedstar-wheels and the portion of the cup mover of FIG. 27A.

FIG. 29 is a cross-sectional side view of one of the cup pockets of oneof the star-wheels of the cup reinforcing system disclosed herein.

FIG. 30 is a front perspective view of one of the in-feed star wheelsand the cup mover of one embodiment of the cup reinforcing systemdisclosed herein illustrating a plurality of cup holders associated witha plurality of centering bells.

FIG. 31A is a side view of the in-feed star wheel and the cup mover ofFIG. 30, illustrating the cup mover positioned adjacent to and slightlybelow the in-feed star wheel.

FIG. 31B is a side view of the in-feed star wheel, the cup mover of FIG.30 and a superstructure which supports the plurality of centering bells.

FIG. 32 is a front perspective view of the bottom member of one of thecup holding stations of the cup mover of one embodiment of the cupreinforcing system.

FIG. 33 is a side view of one embodiment of a centering bell of the cupholding station engaging a cup which is positioned on the bottom memberof the cup holding station of the cup mover.

FIG. 34 is a front perspective view of one embodiment of a centeringbell of a cup holding station of the cup mover.

FIG. 35 is a cross-sectional side view of one embodiment of a centeringbell of the cup holding station engaging a cup which is positioned onthe bottom member of the cup holding station of the cup mover.

FIG. 36 is a schematic block diagram of an electronic configuration ofone embodiment of the cup reinforcing system disclosed herein.

FIG. 37 is a front perspective view of one embodiment of the cup removerof the cup reinforcing system disclosed herein.

FIG. 38A is a top plan view of one embodiment of the reinforcing memberdispenser of the cup reinforcing system disclosed herein.

FIG. 38B is a top plan view of an alternative embodiment of areinforcing member dispenser of the cup reinforcing system disclosedherein, illustrating an alternative design of a release liner slackaccumulator.

FIG. 39 a front perspective view of the reinforcing member dispenser ofFIG. 38A, illustrating the reinforcing member dispenser at anappropriate angle relative to the cup mover.

FIG. 40 an enlarged front perspective view of the reinforcing memberdispenser of FIG. 38A, illustrating a portion of the reinforcing memberdispenser interacting with the cups transported via the cup mover.

FIG. 41A is a diagrammatic top plan view of an alternative embodiment ofthe cup reinforcing system disclosed herein.

FIG. 41B is a diagrammatic top plan view of an alternative embodiment ofthe cup reinforcing system disclosed herein.

FIG. 41C is a diagrammatic top plan view of an alternative embodiment ofthe cup reinforcing system disclosed herein.

FIG. 41D is a diagrammatic top plan view of an alternative embodiment ofthe cup reinforcing system disclosed herein.

FIGS. 42A to 42E are perspective views of the interaction between thecup mover and the reinforcing member dispenser of one embodiment of thecup reinforcing system disclosed herein.

FIGS. 43A to 43F are diagrammatic top plan views of the cup reinforcingsystem disclosed herein, illustrating one embodiment of the attachmentof a reinforcing member to a plastic foam cup.

FIGS. 44A to 44D are diagrammatic top plan views of an alternativeembodiment of the cup reinforcing system disclosed herein.

DETAILED DESCRIPTION

The present disclosure relates in general to a reinforced drinking cupand more particularly to a disposable plastic foam reinforced drinkingcup and a method of and apparatus for manufacturing the same. Thereinforced drinking cup is particularly suitable for carrying ortransporting hot beverages, such as coffee, tea and hot chocolate orother products.

Referring now to FIGS. 3 and 4, a reinforced plastic foam cup 30 of oneembodiment disclosed herein is formed from the process of reinforcing abase cup (such as a conventional plastic foam cup described above) witha reinforcing member as described below. The reinforcing cup 30 includesa body 32 which defines an open top end 34 and a closed bottom end 36,wherein the top end has a greater diameter than the bottom end. The bodyincludes a tapered side wall 38 that extends from the bottom end to thetop end. The top end of the body includes an outwardly formed lip 40,however the cup does not need to have a formed lip. It should beappreciated that the plastic foam base cup may be formed from anysuitable material, such as beaded polystyrene. In another embodiment,the base cup includes a paper based cup suitably coated or otherwiselaminated with one or more layers of polystyrene.

Unlike a conventional plastic foam base cup, a reinforcing member 42 isattached to almost all of or a substantial portion of the outer surfaceof the tapered side wall 38 to provide increased tactile feel, supportand rigidity to the tapered side wall. Accordingly, as best seen in FIG.4, the tapered side wall 38 of the reinforced plastic foam cup 30includes a plastic foam layer 44, a pressure sensitive adhesive layer 46and a rigid material layer 48 which provides a better tactile feel.Compared to a non-reinforced plastic foam cup which only includes aplastic foam layer, the reinforced plastic foam cup with themulti-layered tapered side wall (i.e., the plastic foam layer 44, theadhesive layer 46 and the rigid material layer 48) provides asubstantial increase in the tactile feel and rigidity of the reinforcedplastic foam cup. Accordingly, the reinforced plastic foam cup providesa disposable cup with the insulation properties of a plastic foam cupand also the tactile feel of a paper-based cup. Such reinforced plasticfoam cup costs less than a paper-based cup with comparable insulationproperties (i.e., such as a nested paper-based cup). Moreover, asdescribed in one embodiment below, when graphics are printed on theouter face of the rigid material of the reinforcing member, thereinforced plastic foam cup further provides a disposable cup with thehigh-quality graphic presentation properties of a paper-based cup.

Referring now to FIGS. 5 to 7, in one embodiment, a reinforcing memberor reinforcer 42 includes a body 50 formed from a malleable, rigidmaterial, such as a suitable paper, a suitable plastic stock, a suitablecomposite material or any other suitable material. The body 50 issubstantially planar or flat with a thickness in the range 1.5millimeters to 8.0 millimeters, and in one preferred embodiment athickness in the range of approximately 2.7 millimeters to 4.0millimeters. As best illustrated in FIG. 6, in one embodiment, an innerface or surface 52 of the flat body 50 of the reinforcing member 42 iscompletely or substantially completely coated with an adhesive andpreferably a pressure sensitive adhesive 54. It should be appreciatedthat any suitable adhesive or bonding agent which completely orsubstantially completely coats the inner face of the reinforcing membermay be employed. As seen in FIG. 7, in one embodiment, the adhesivecoating of the reinforcing member 42 is releasably attached to asuitable elongated release liner 56 which enables the reinforcing memberto be handled without the adhesive exposed. In this embodiment, asdescribed in more detail below, a plurality of reinforcing members 42are sequentially positioned linearly along a single release liner 56.The release liner 56 may be made of any suitable material, such as asuitable plastic, paper or any combination thereof. For example, therelease liner is an approximately forty pound craft paper.

In one embodiment, as illustrated in FIG. 5, an outer face or surface 58of the flat body 50 includes one or more suitable branding areas 60where high quality graphics, such as a company's logo or suitablemarketing graphics, text and/or images are printed thereon. In oneembodiment, a laminate material or a protective coating (not shown) isapplied to the outer face over the layer(s) of ink to protect and/orenhance the printed matter.

In one embodiment, the flat body 50 is defined by a curved or annularedge 62, a curved or annular edge 64, an angled front or leading edge 66and an angled rear or trailing edge 68. In one embodiment, the edge 62of the reinforcing member is suitably concavely shaped and the edge 64is suitably convexly shaped, wherein a trough of the concavely shapededge and an apex of the convexly shaped edge reside in the same verticalplane. In one embodiment, the length of the edge 62 is less than thelength of the edge 64 such that the leading edge 66 is angled offsetfrom a vertical plane at a suitable angle (A degrees) and the trailingor rear edge 68 is also angled offset from a vertical plane at asuitable angle (B degrees). A sensing edge 70 which includes a portionof the leading edge adjacent to edge 64 extends vertically orsubstantially vertically. As described in more detail below, the sensingedge is utilized in determining the exact location of the reinforcingmember as well as preventing leakage of the adhesive when a plurality ofreinforcing members releasably attached to a release liner are woundinto a supply roll.

In another embodiment, as seen in FIGS. 5A, 6A and 7A, in addition to asensing edge 70 (i.e., a portion of the leading edge adjacent to edge 64extending vertically or substantially vertically), the reinforcingmember includes an adhesive relief edge 72. The adhesive relief edge isa vertically or substantially vertically extending portion of thetrailing edge adjacent to edge 64 of the reinforcing member. In oneembodiment, the sensing edge and the adhesive relief edge are the samelength or substantially the same lengths. In another embodiment, thesensing edge and the adhesive relief edge are different lengths orsubstantially different lengths. It should be appreciated that while thesensing edge and adhesive relief edge are displayed adjacent to edge 64of the reinforcing member, the sensing edge may be located at anyposition along the leading edge and/or the adhesive relief edge may belocated at any position along the trailing edge. It should be furtherappreciated that the reinforcing members are displayed in an upside downposition to match the upside down cups which they will engage with asdescribed below. Accordingly, as best seen in FIG. 5B, the graphics 60printed on the reinforcing member may printed in any suitableconfiguration.

It should be appreciated that when a plurality of reinforcing membersare positioned linearly along the elongated release liner to form astock or supply roll of reinforcing members and the release liner iswound about a central cylindrical tube into a roll, a relativelysignificant amount of pressure is placed on one or more of the woundreinforcing members, especially on the inner reinforcing members whichare wound at greater angles (because of roll has a smaller diameter atsuch points). This pressure tends to cause the adhesive coating on suchwound reinforcing members to leak from the point where the leading edgeand the curved or annular bottom edge intersect and/or the point wherethe trailing edge and the curved or annular bottom edge intersect.Leaking of the adhesive coating from these points may damage one or moreof the wound reinforcing members and/or build-up on the release linerseparator or separation plate (as described below). This leakingadhesion may also prevent the reinforcing member from properly adheringto the cup in the desired manner. In one embodiment of the presentdisclosure, the sensing edge and the adhesive relief edge eachredistribute the formed pressure from these respective points on thereinforcing member to an extended portion of the reinforcing member.This redistribution relieves the pressure which forms and thus reducesor prevents the leaking of the adhesive coating from one or more of thewound reinforcing members.

It should be appreciated that the dimensions of the reinforcing memberwill be specific to the specifications of the base cup. Therefore, therespective angles of the leading and trailing edges of the reinforcingmember, the shape of the top and bottom edges, the length between theleading edge and the trailing edge or any other suitable dimensions ofthe reinforcing member will be based on the size of the base cup, theangle of the tapered side wall of the base cup or any otherspecification of the base cup. It should be further appreciated thatwhen the reinforcing member is initially attached to the cup, asdescribed below, the sensing edge 70 is: (i) perpendicular orsubstantially perpendicular to the bottom edge of the cup; and (ii)parallel to the centered vertical axis of the reinforcing member. Such aconfiguration provides an absolute reference point for the cupreinforcing system to determine the location of the reinforcing member.

For example, in one embodiment, if the base cup is a twelve ounce cup,the reinforcing member is configured such that the angle between theconcave edge and leading edge is approximately ninety degrees, the anglebetween the concave edge and trailing edge is approximately ninetydegrees, the angle between leading edge and the sensing edge isapproximately one-hundred-fifty degrees, the angle between the trailingedge and adhesive relief edge is approximately one-hundred-fiftydegrees, the angle between the convex edge and the sensing edge isapproximately one-hundred-twenty degrees, and the angle between theconvex edge and the adhesive relief edge is approximatelyone-hundred-twenty degrees.

In another example, if the base cup is a sixteen ounce cup, thereinforcing member is configured such that the angle between the concaveedge and leading edge is approximately ninety degrees, the angle betweenthe concave edge and trailing edge is approximately ninety degrees, theangle between leading edge and the sensing edge is approximatelyone-hundred-fifty-five degrees, the angle between the trailing edge andadhesive relief edge is approximately one-hundred-fifty-five degrees,the angle between the convex edge and the sensing edge is approximatelyone-hundred-fifteen degrees, and the angle between the convex edge andthe adhesive relief edge is approximately one-hundred-fifteen degrees.

In another example, if the base cup is twenty ounce cup, the reinforcingmember is configured such that the angle between the concave edge andleading edge is approximately ninety degrees, the angle between theconcave edge and trailing edge is approximately ninety degrees, theangle between leading edge and the sensing edge is approximatelyone-hundred-sixty degrees, the angle between the trailing edge andadhesive relief edge is approximately one-hundred-sixty degrees, theangle between the convex edge and the sensing edge is approximatelyone-hundred-ten degrees, and the angle between the convex edge and theadhesive relief edge is approximately one-hundred-ten degrees.

In general, as illustrated in FIG. 8, the method or process ofmanufacturing the above-described reinforced plastic foam cup includesdetermining a vertical axis which runs through a center point of the topand bottom edge of the reinforcing member as indicated in block 80. Themethod includes positioning the base or pre-reinforced plastic foam cupupside-down and positioning the reinforcing member adjacent to thetapered side wall of the upside-down base cup at an angle whichcorresponds with the angle of the tapered side wall of the base cup asindicated in blocks 82 and 84. At the point when both the base cup andthe reinforcing member move into position, as indicated in block 86, theinside face of the reinforcing member is attached to the outer face ofthe tapered side wall of the base cup along the determined centeredvertical axis, wherein the reinforcing member is attached at an anglewhich corresponds with the angle of the tapered side wall of the basecup. After attaching the center of the reinforcing member to the taperedside wall of the base cup, the cup with the reinforcing member continuesto move on the cup conveyer and the remaining free or unattachedportions are sequentially or simultaneously attached to the tapered sidewall as indicated in block 88. It should be appreciated that suchangling of the reinforcing member provides that as the remainingunattached portions or sections of the reinforcing member are attachedto the tapered side wall of the base cup, the reinforcing member willcompletely adhere to the tapered side wall of the base cup.

More specifically, as diagrammatically seen in FIG. 9, in oneembodiment, the method or process of manufacturing or sequentiallyreinforcing at least one and preferably a plurality of individualplastic foam cups includes utilizing a processor controlled cupreinforcing system or apparatus 100. In one embodiment, the cupreinforcing system includes a cup conveyer system which moves the cupinto the attachment position and transports or moves one or more base orpre-reinforced plastic foam cups 102 throughout the cup reinforcingsystem 100 in a conventional manner. The cup reinforcing system furtherincludes at least one reinforcing member dispenser 104 operable tosequentially feed each reinforcing member toward the attachment positionfor attachment to the individual base cup 102. The cup reinforcingsystem also includes a suitable sensor 106 operable to determine thelocation of each reinforcing member, wherein based on such determinedlocation, the cup reinforcing system 100 aligns a centered vertical axis108 of the reinforcing member 42 with the tapered side wall of anindividual base cup 102. Accordingly, a system or apparatus forattaching a reinforcing member to a cup includes a cup conveyor system,a reinforcing member dispenser (i.e., a device for centering andaffixing or attaching the reinforcing member to the outer surface of thetapered side wall of the cup). It should be appreciated that anysuitable cup reinforcing system may be implemented in accordance withthe disclosed process of reinforcing a plastic foam cup

In one embodiment, as further described and illustrated below, the cupconveyer includes one or more individual cup positions wherein eachindividual cup position includes a rotationally mounted cup holdingturntable with a suitable cup positioning device to suitable positionthe cup at a set position on the cup holding turntable. The cup holdingturntable is also operable to rotate the cup a full 360 degrees inclockwise and counterclockwise directions. In one embodiment, the cuppositioning device includes a frictional engagement member or mandrelwhich frictionally engages the inner face of the wall of the base cup tofix the cup in the suitable position on the turntable. In operation, abase cup 102 is placed face down (i.e., resting on the open top end) onthe cup conveyer system and the cup is moved into a position thatfacilitates engagement with the reinforcing member.

In one embodiment, as illustrated in FIGS. 9 and 10, the reinforcingmember dispenser 104 is operable (via one or more suitable rollers 110)to feed the reinforcing member in the direction of a face down base cup.In one embodiment, the reinforcing member dispenser 104 is configured orshaped to define or include a release liner separation section 112. Inthis embodiment, based on the orientation of the reinforcing member 42relative to the release liner separation section 112, the reinforcingmember 42 will separate from the release liner 56 (which protects thepressure sensitive adhesive) when the reinforcing member is fed throughthe release liner separation section 112. In one embodiment, the cupreinforcing system also includes one or more reinforcing memberapplication pad(s) 114 which operate to guide the reinforcing member andprevent the reinforcing member from shifting positions after a portionof the reinforcing member 42 separates from the release liner 56.

As best seen in FIG. 11, in one embodiment, the reinforcing memberdispenser is operable to feed the release liner 56 (which thereinforcing member is releasably attached to) toward the base cup 102 ata suitable angle offset from a vertical plane which corresponds with theangle (also offset from a vertical plane) of the tapered side wall ofthe base cup. In this embodiment, when the reinforcing member 42separates from the release liner 56, the reinforcing member will bepositioned at a suitable angle which corresponds with the angle of thetapered side wall of the base cup 102. In one embodiment, thereinforcing member engages the tapered side wall of the base cup at asuitable angle offset from a vertical plane while both the cup and thereinforcing member are moving. As described in more detail below, suchangling provides that the reinforcing member will completely adhere tothe tapered side wall of the base cup.

Referring back to FIGS. 9 and 10, as described above, the cupreinforcing system also includes at least one sensor 106 for determiningor verifying the location or position of the reinforcing member 42relative to the position of the base cup 102. In one embodiment, thesensor detects the location of the substantially vertical portion orsensing edge 70 of the front or leading edge of the reinforcing member42 to determine the relative position of the reinforcing member. Basedon this determined position of the reinforcing member 42 and any othersuitable information (such as the speed the cup is moving, the speed thereinforcing member is being fed through the reinforcing memberdispenser, the length of the reinforcing member and the diameter of thecup), the processor of the cup reinforcing system determines orcalculates when the reinforcing member 42 is moved into a position inwhich a centered vertical axis 108 of the reinforcing member 42 isaligned with the tapered side wall of the base cup 102. In thisembodiment, the centered vertical axis 108 is the vertical axis thatruns through both the trough of the concavely shaped top edge 62 of thereinforcing member and the apex of the convexly shaped bottom edge 64 ofthe reinforcing member.

In one embodiment, at least one sensor is positioned or placed such thatthe sensor detects the exact location of each reinforcing memberimmediately prior to that reinforcing member being affixed to a basecup. In this embodiment, positioning the sensor at such a positionprovides for increased accuracy in the placement of the reinforcingmember on the base cup which, as described in more detail below,provides for a proper engagement between the reinforcing member and thecup. In alternative embodiments, the alignment process is controlled bysuitable timing mechanisms wherein one or more sensors are utilized toverify that the timing mechanisms are correct. In the illustratedembodiment, the sensor senses the sensing edge. However, it should beappreciated that the sensor could sense another suitable reinforcingmember position indicator.

As seen in FIGS. 12, 13 and 14, in one embodiment, the processor of thecup reinforcing system causes the cup conveyer to move the cup 102 intothe attachment position and causes the reinforcing member dispenser 104to feed the reinforcing member 42 into the attachment position where thecentered vertical axis 108 of the reinforcing member 42 is aligned withthe tapered side wall of the base cup 102, and causes the inner face 52of the reinforcing member 42 (which is completely or substantiallycompletely coated with a pressure sensitive adhesive 54) to be initiallyattached to the tapered side wall of the cup along the centered verticalaxis (as best seen in FIG. 13). In this embodiment, it should beappreciated that both the cup and the reinforcing member are movingprior to and through the point of attachment of the reinforcing memberto the outer surface of the tapered side wall of the cup. In oneembodiment, the cup conveyer moves the base cup into a position whichengages the reinforcing member application pad 114, such that thetapered side wall of the cup presses against or engages the reinforcingmember application pad to cause the reinforcing member 42 (which ispositioned between the tapered side wall and the reinforcing memberapplication pad 114) to engage the tapered side wall of the cup 102 asbest seen in FIG. 14.

As described above and best seen in FIG. 14, the reinforcing member 42is situated at an angle which corresponds with the angle of the taperedside wall of the cup and thus the reinforcing member is attached to thebase cup at an angle which corresponds with the angle of the wall of thebase cup. Moreover, as seen in FIG. 13, after the reinforcing member isinitially attached to the cup along the centered vertical axis of boththe reinforcing member and the cup, the leading edge 66 and trailingedge 68 of the reinforcing member remain unattached or are otherwisefree. It should be appreciated that because the cup is placed open enddown, the top edge 62 of the reinforcing member adheres to the taperedside wall at (or substantially adjacent to) the bottom end of the cupand the bottom edge 64 of the reinforcing member adheres to the taperedside wall at (or substantially adjacent to) the top, open end of thecup. It should be further appreciated that based on manufacturingtolerances, the reinforcing member may be attached to the cup slightlyoffset from the centered vertical axis of the reinforcing member, and inone embodiment in a range of plus or minus three degrees.

As illustrated in FIG. 15, after the reinforcing member 42 is attachedto the tapered side wall of the cup 102 along the centered vertical axis108 of the reinforcing member, the cup reinforcing system 100 isoperable to cause the remaining unattached portions of the reinforcingmember to engage and attach to the tapered side wall of the cup. In oneembodiment, utilizing the turntable on which the cup resides, the cuprotates 180 degrees in a first direction. As the cup is rotating, thetapered side wall of the cup 102 presses against or engages thereinforcing member application pad 114 to cause a first portion orsection of the reinforcing member to engage and thus, due to thepressure sensitive adhesive coating 54 on the reinforcing member 42,attach to the tapered side wall of the cup. In one embodiment, the firstportion or section includes the portion of the reinforcing member 42which extends from the centered vertical axis 108 to the trailing edge68. Accordingly, as seen in FIG. 16, after the first section of thereinforcing member is attached to the tapered side wall of the cup, asecond section of the reinforcing member remains unattached or isotherwise free.

As seen in FIG. 17, in one embodiment, following a rotation of the cupin a first direction, the cup is then rotated 360 degrees in anopposite, second direction. As the cup is rotating, the tapered sidewall of the cup presses against or engages the reinforcing memberapplication pad 114 to cause the second portion or section of thereinforcing member to engage and attach to the tapered side wall of thecup. In one embodiment, the second portion or section includes theportion of the reinforcing member 42 which extends from the centeredvertical axis to the leading edge. As described above, the shape orconfiguration of the reinforcing member coupled with the shape orconfiguration of the cup provides that as the remaining portions of thereinforcing member are attached to the cup, the reinforcing member willaffix to the tapered side wall of the cup in the desired configuration(i.e., the cup pulls to the reinforcing member and the reinforcingmember pulls to the cup). The reinforced plastic foam cup provides adisposable drinking cup with the insulation properties of a plastic foamcup and the tactile feel and high quality graphic printing properties ofa paper-based cup to provide an enhanced drinking experience for aperson.

In one alternative embodiment, the cup reinforcing system may beconfigured with a plurality of reinforcing member application pads whichare positioned on opposite sides of the cup such that the cup is rotated180 degrees in a first direction to attach the first portion of thereinforcing member to the cup, followed by rotating the cup 180 degreesin the second direction to attach the second portion of the reinforcingmember to the cup. After the rotation in the second direction, thereinforcing member is completely adhered to the base cup and thereinforced plastic foam cup 30 described above (and illustrated in FIGS.3 and 4) is formed. It should be appreciated that any suitable apparatusfor or method of attaching the reinforcing member to the tapered sidewall along the centered vertical axis may be implemented in accordancewith the present disclosure.

It should be appreciated that in one embodiment, as seen in FIG. 17, thecup reinforcing system is operable to sequentially reinforce one or moreindividual cups. In this embodiment, one or more cups are each placedface down and suitably spaced apart on the cup conveyer. Moreover, oneor more reinforcing members are positioned linearly along a singlerelease liner and wrapped in a supply roll. The supply roll is threadedabout the reinforcing member dispenser to provide a continuous feed ofreinforcing members.

In another embodiment (not shown), the cup is placed on the cup conveyerresting on its closed bottom end. In another embodiment (not shown), thereinforcing member dispenser is positioned such that the reinforcingmember engages the tapered side wall of the cup situated in a verticalplane. Accordingly, in this embodiment, the cup conveyer is configuredat a suitable angle to provide that the tapered side wall of the cupengages the reinforcing member in the vertical plane as well. In anotherembodiment, the cup conveyer is suitably angled and the cup istransported throughout the cup reinforcing system at such an angle. Inthese embodiments, the reinforcing member dispenser and/or thereinforcing member application pads are accordingly adjusted to anysuitable angle to account for the angle of the cup and/or reinforcingmember to insure that the reinforcing member is initially affixed to thetapered side wall of the cup at an angle which corresponds with thetapered side wall of the cup.

In one alternative embodiment, the cup reinforcing system and apparatusdisclosed herein is operable to reinforce a newly formed cup 40 a beforethe newly formed cup shrinks, fully cures or settles to its stableproportions. This embodiment substantially eliminates the costlyoverhead otherwise associated with storing newly formed cups while theyshrink or settle prior to being ready to be reinforced or otherwisefurther processed. In this embodiment, as illustrated in FIGS. 3A and4A, a modified reinforcing member 90 is applied (as described above) toa newly formed cup 40 a wherein the width of the modified reinforcingmember is less than the circumference of the newly formed cup (afterformation but prior to full shrinkage). Specifically, a length of theconcavely shaped top edge of the reinforcing member is less than thelength of the diameter or circumference of the top end of the plasticfoam cup (after formation but prior to full shrinkage) and a length ofthe convexly shaped bottom edge of the reinforcing member is less thanthe length of the diameter or circumference of the bottom end of theplastic foam cup (after formation but prior to full shrinkage). Such aconfiguration provides that when the reinforcing member is applied tothe cup, an elongated gap 92 exists between the leading edge of thereinforcing member 66 a and the trailing edge of the reinforcing member68 a. For example, when a modified reinforcing member is applied to anewly formed twelve ounce cup at a point in time during the shrinking ofthe newly formed cup, a gap of thirty to thirty-five thousandths of aninch exists between the leading edge of the reinforcing member and thetrailing edge of the reinforcing member. As seen in FIG. 3A, the gapextends substantially the height of the reinforcing member.

In this embodiment, as seen greatly enlarged in FIGS. 4A, 4B and 4C, asthe expanded polystyrene of the newly formed cup settles or shrinks overa designated period of time, such as seven to twenty-five days, thedimensions of the reinforced cup change and the width of the gap betweenthe leading edge of the reinforcing member and the trailing edge of thereinforcing member closes. That is, as illustrated in FIG. 4C, after adesignated period of time, the expanded polystyrene of the reinforcedcup has shrunk to a stable size and since the reinforcing member isaffixed to the cup as it shrinks, the leading and trailing edges of thereinforcing member are brought together to close or substantially closethe existing gap. It should be appreciated that this embodiment enablesa reinforced cup manufacturer to ship the newly formed, reinforced foamcups after the reinforcing member is applied, wherein the cups willshrink during shipment to close or substantially close the existing gap.Accordingly, this embodiment provides a cup reinforcing system orapparatus which reinforces newly formed cups and eliminates the costlyoverhead otherwise associated with storing newly formed cups prior tobeing ready to be reinforced or otherwise further processed.

Referring now to FIGS. 18A to 43F, various embodiments of the cupreinforcing system or apparatus disclosed herein are illustrated andgenerally indicated by numeral 200. As illustrated in FIGS. 18A and 18B,the cup reinforcing system 200 generally includes a cup conveyor system202 and one or more reinforcing member dispensers 204 a and 204 b(referred to generally as 204). The cup conveyor system is configured toreceive each pre-reinforced cup, transport and space such received cupsinto an appropriate position for attachment of a reinforcing member andremove each cup from the cup reinforcing system after the attachment ofa reinforcing member to that cup. Each reinforcing member dispenser 204is configured to transport each reinforcing member into the appropriateposition for attachment with the transported cups and attach eachreinforcing member, along a centered vertical axis of the reinforcingmember, to the wall of one of the upside down positioned cups at anangle which corresponds with the angle of the tapered side wall of thecup.

More specifically, the cup conveyor system includes a cup dispenser 206,a cup feeder 208, a cup spacer 210, a cup mover 212, and a cup remover214. As generally illustrated in FIG. 36, the processor 402 of the cupreinforcing system is in communication with and programmed to controlthe cup dispenser 206, the cup feeder 208, the cup spacer 210, the cupmover 212, the cup remover 214, and the reinforcing member dispenser204. The processor is also in communication with and programmed tocontrol at least one input device or control panel 404, such as a touchscreen or one or more suitable switches or buttons, for enabling a userto operate the cup reinforcing system and at least one display device406 for displaying suitable information to a user of the cup reinforcingsystem. The input device enables a user to input appropriate commandsand/or suitable information to the processor of the cup reinforcingsystem. For example, a user utilizes at least one input device toinitiate and shut-off the cup reinforcing system, provide informationregarding the exact specifications of the cups and/or reinforcingmembers, input the speed to move the cups throughout the cup reinforcingsystem, and input the angle to set the reinforcing member dispenserrelative to the cup mover. In another embodiment, one or more of thefunctions described above may be manually adjusted utilizing one or moremechanical or other suitable devices. For example, the angle to set thereinforcing member dispenser relative to the cup mover may be manuallyadjusted utilizing one or more individual hand cranks.

The processor is in communication with or operable to access or toexchange signals with at least one data storage or memory device 408.The memory device stores program code and instructions, executable bythe processor, to control the cup reinforcing system. In one embodiment,the memory device includes random access memory (RAM), which can includenon-volatile RAM (NVRAM), magnetic RAM (MRAM), ferroelectric RAM (FeRAM)and other forms as commonly understood in the art. In one embodiment,the memory device includes read only memory (ROM). In one embodiment,the memory device includes flash memory and/or EEPROM (electricallyerasable programmable read only memory). Any other suitable magnetic,optical and/or semiconductor memory may operate in conjunction with thecup reinforcing system disclosed herein. In one embodiment, part or allof the program code and/or operating data described above can be storedin a detachable or removable memory device, including, but not limitedto, a suitable cartridge, disk, CD ROM, DVD or USB memory device. Theprocessor and memory device may sometimes be collectively referred toherein as a “computer” or “controller.”

As described in more detail below, a pre-reinforced or base cup entersthe cup reinforcing system via the cup dispenser 206 from a supply ofnested cups. The cup travels via the cup feeder 208 to the cup spacer210 and then to the cup mover 212. The cup mover 212 aligns the cup intothe appropriate alignment with the reinforcing member dispenser 204 andthe reinforcing member is attached or affixed to the cup by thereinforcing member dispenser 204. The reinforced cup is removed from thecup reinforcing system via the cup remover 214. It should be appreciatedthat any other suitable cup conveyor system and any suitable reinforcingmember dispenser which attaches a reinforcing member to the tapered sidewall of a base cup along the centered vertical axis of the reinforcingmember and subsequently attaches the remaining portions of thereinforcing member to the tapered side wall of the base cup may beimplemented in accordance with the cup reinforcing system disclosedherein.

As seen in FIGS. 19 to 22, the cup dispenser 206 of the cup reinforcingsystem includes a frame 230 which supports two independent, offset guidemembers 232 a and 232 b (referred to generally as 232). Each guidemember is configured to hold a stack of nested pre-reinforced or basecups 234 a and 234 b (referred to generally as 234) in upside downpositions above the cup feeder 206. Each guide member 232 is associatedwith at least one and preferably a plurality of or set of vertically orsubstantially vertically disposed co-acting cup dispensing screws or cupde-nesters 236 a, 236 b, 236 c and 236 d (referred to generally as 232and as best seen in FIGS. 20 and 21) made of any suitable smoothsurfaced, non-abrasive material with self-lubrication properties, suchas any suitable plastic, for example a DELRIN® plastic manufactured byE. I. DU PONT DE NEMOURS AND COMPANY.

Each cup dispensing screw 236 has internally extending threading 238 onits outer surface. The threads are suitably sized and angled tocorrelate to the top lips of the upside down positioned base cups 102held by the guide members 232. The cup dispensing screws 236 are eachmovably connected or coupled to at least one actuator 240, such as amotor or other suitable movement generating device controlled by the cupreinforcing system processor which causes each cup dispensing screw 236to rotate in the appropriate direction at a suitable speed.

In operation, as best seen in FIGS. 19 and 21, the internal threadinglocated at or near the top 238 a of each rotating cup dispensing screw236 engage a portion of the outwardly extending lip 24 of a first nestedupside down cup held by one of the guide members 232. Each cupdispensing screw rotates to pull the first cup, via the top threading238 a of each cup dispensing screw which engages the cup lip 24, fromthe nested set of cups 234. As each cup dispensing screw 236 continuesto rotate, the cup lip 24 of the first cup is passed to the threadinglocated at or near the middle 238 b of each rotating cup dispensingscrew and then to the threading located at or near the bottom 238 c ofeach rotating cup dispensing screw to slowly and consistently pull thefirst cup further away from the nested set of cups 234. As the first cupis passed from the top threading 238 a of each cup dispensing screw tothe middle threading 238 b, the top threading 238 a engages the lip 24of a second nested upside down cup to pull the second cup, via the topthreading 238 a engaging the lip of the second cup, from the nested setof cups 234. This process continues to separate each nested cup from theset of nested, upside-down cups loaded into the cup dispenser 206. Inother words, the rotating threads of the cup dispensing screws co-act toseparate each engaged cup, one at a time, from the nested stack ofpre-reinforced upside down cups. After being de-nested, each separatedcup 102 proceeds to drop down to the cup feeder 208 located directlybelow the cup dispenser 206.

In one alternative embodiment, the cup dispenser includes more than twoindependent, offset guide members. In this embodiment, each guide memberholds a stack of nested pre-reinforced cups and is further associatedwith at least one and preferably a plurality of vertically disposed cupdispensing screws as described above. In another alternative embodiment,one guide member is configured to hold a plurality of stacks of nestedpre-reinforced cups above a plurality of different locations of the cupfeeder. In this embodiment, the guide member is associated with at leastone and preferably a plurality of vertically disposed cup dispensingscrews for each held stack of pre-reinforced cups. In anotheralternative embodiment, one guide member is configured to hold one stackof nested pre-reinforced cups above a single location of the cup feeder.In this embodiment, the guide member is associated with at least one andpreferably a plurality of vertically disposed cup dispensing screws forthe held stack of pre-reinforced cups. It should be appreciated that anysuitable apparatus or method for loading one or more pre-reinforced cupsonto the cup feeder may be implemented in accordance with the cupreinforcing system disclosed herein. It should be further appreciatedthat the cup dispenser disclosed herein may be located at any suitableposition upstream from the reinforcing member dispenser described below.

As seen in FIGS. 19 and 22 to 24, the cup feeder 208 of the cup conveyorsystem includes a frame 250 which supports a plurality of rows ofadjacently positioned conveyor belts 252 a to 252 e (referred togenerally as 252). The conveyor belts are suitably movably connected orcoupled to at least one actuator, such as a motor or other suitablemovement generating device 254 which causes the conveyor belts to moveat any suitable speed in a conventional manner.

It should be appreciated that static electricity can build up by rapidmovement of plastic foam cups. The use of multiple guide members 232 andmultiple cup dispensing screws 236 reduces the likelihood of staticelectricity buildup in the cup reinforcing system disclosed herein. Thatis, the use of multiple guide members and multiple cup dispensing screwsreduces the number of cups each individual guide member/cup dispensingscrew must dispense per minute. This reduced number of cups directlycorrelates to a reduction in the speed which cups must be transportedthroughout the cup reinforcing system and such a reduction in speedreduces the amount of static electricity buildup.

In one embodiment, one, more or each of the conveyor belts 252 defineone or more apertures or holes 256 through which air flows as describedbelow. As best illustrated in FIGS. 22, 24A and 24B, the conveyor beltswhich are positioned or aligned beneath or under the offset guidemembers 232 a and 232 b, in this case conveyor belts 252 a and 252 e,define larger diameter apertures or holes 256 a than the apertures orholes 256 b of the conveyor belts which are not positioned under theoffset guide members, in this case conveyor belts 252 b, 252 c and 252d. It should be appreciated that any suitable number of holes, of anysuitable diameter and of any suitable shape (such as elongated ovalshaped holes) which allows an adequate amount of air flow as describedbelow, may be implemented in accordance with the cup reinforcing systemdisclosed herein.

As illustrated in FIGS. 23, 24A and 24B, the frame 250 of the cup feeder208 supports a vacuum chamber, box or housing 258. The vacuum box 258includes a top wall or surface 260 and a spaced apart bottom wall orsurface 262. The top wall defines a plurality of apertures or air inlets264. The vacuum box includes spaced apart side walls 268, wherein thetop of each side wall is connected to the top wall and the bottom ofeach side wall is connected to the bottom wall. The vacuum box alsoincludes spaced apart end walls 270 a and 270 b, wherein the top of eachend wall is connected to the top wall, the bottom of each end wall isconnected to the bottom wall, one side of each end wall is connected toone side wall and the other side of each end wall is connected to theother side wall. At least one side wall of the vacuum box (side wall 270a of FIG. 24A and side walls 270 a and 270 b of FIG. 24B) each definesone or more apertures or air outlets 272 which are connected, viasuitable air communication lines, to one or more vacuum or negativepressure sources (not shown). That is, the vacuum chamber is in fluidcommunication with a suitable vacuum or negative pressure source.

In one alternative embodiment, as seen in FIG. 24C, the frame 250 of thecup feeder includes two air flow members 274 a and 274 b spaced belowthe offset guide members of the cup dispenser. In this embodiment, eachair flow member is connected to a vacuum or negative pressure sourcewhich pulls each base cup from the cup dispenser. It should beappreciated that in this embodiment, air only flows through the largerdiameter holes in the conveyor belt (located directly above the air flowmember) and not through the smaller diameter holes, if any, in theconveyer belt not located directly above the air flow member.

As specifically illustrated in FIG. 24, the vacuum source providesnegative air flow from the area above the conveyer belts 252, throughthe holes 264 of the conveyer belts, the air inlets 256 of the topsurface 260 of the vacuum box and the defined air outlet 272 of thevacuum box to the vacuum source. In operation, each separated base cupis pulled downwardly by the vacuum pressure, in a face down position,from the cup dispenser 206 onto the cup feeder 208. It should beappreciated that positioning the larger apertures 256 a of certain ofthe conveyer belts under the offset guide members 232 of the cupdispenser 206 provides for an increased amount of air to flow from abovethe conveyor belts 252, through the larger apertures 256 a and to thevacuum source (not shown) near the location where the cup dispenser 206drops the cups 102. It should be further appreciated that vacuumpressure applied to the cups provides that the relatively light-weightbase cups (as opposed to a heavier bottle) do not tip over when they aredropped from the cup dispenser 206 to the cup feeder 208.

The cup reinforcing system is configured to move the cups along theconveyor belts at a relatively slow speed when compared to the speedswhich bottles are moved though a bottle labeling system. That is, whilebottles of a bottle labeling system are typically labeled atapproximately one-thousand bottles per minute, the disclosed cupreinforcing system applies reinforcing members to base cups at less thanhalf the rate of such bottle labeling systems. As mentioned above, sucha reduction in the speed which the cups are moving through the cupreinforcing system eliminates static electricity buildup often caused byrapid movement of plastic foam cups.

As seen in FIG. 22 and 24, the cup feeder 208 includes at least twoopposing spaced-apart elongated guide rails or guide tracks 266 a and266 b (referred to generally as 266) supported by the frame 250 of thecup feeder. The guide rails 266 are angled offset from a vertical planeat a suitable angle to match the angle of the tapered side walls of thecups transported by the conveyor belts 252. Guide rail 266 a and 266 bextend in intersecting planes such that the space between the two guiderails 266 is reduced as the guide rails extend out from an areasubstantially below the cup dispenser 206. In operation, as each cup 102moves along the conveyor belts 252 of the cup feeder 208 in thedirection of the cup spacer 210, each cup engages one of the guide rails266. As the cups move closer to the cup spacer, the engagement with theguide rails 266 causes the cups to move into a single-file order. Itshould be appreciated that the cup feeder may include any suitableapparatus or method for transporting the cups from the cup dispenser tothe cup spacer.

As illustrated in FIGS. 25 to 27B, the cup spacer 210 of the cupconveyor system includes a frame 280 positioned adjacent to and atsubstantially the same height as the cup feeder 208. As seen in FIG.27A, the frame of the cup feeder supports an in-feed screw or spacingscrew 282 and two co-acting inlet stars or in-feed star-wheel conveyors284 a and 284 b (referred to generally as 284). As seen in FIG. 27B, inone embodiment, the frame of the cup feeder supports an in-feed screw orspacing screw 282 and one inlet star or in-feed star-wheel conveyor 284a. In these embodiments, the cup spacer 210 is utilized to transport theeach cup 102 from the cup feeder 208 to the cup mover 212.

The in-feed screw or spacing screw 282 of the cup spacer 210 is ahorizontally or substantially horizontally disposed member made of anysuitable smooth surfaced, non-abrasive material with self-lubricationproperties, such as any suitable plastic, for example a DELRIN® plasticmanufactured by E. I. DU PONT DE NEMOURS AND COMPANY. The spacer screwhas internally extending threading 286 on its outer surface. Thethreading 286 is suitably sized and angled to correlate to the taperedside wall of the cups. As seen in FIGS. 25 and 26, the space between thethreads of the spacer screw gradually and consistently increase from afirst end 294 of the spacer screw adjacent to the cup feeder 208 to asecond end 296 of the spacer screw adjacent to the cup mover 212. Theincreased spacing between the spacer screw threads provides that as eachcup 102 is transported from the first end 294 of the spacer screw to thesecond end 296 of the spacer screw, each cup (which is engaged by aportion of the threading of the spacer screw) is suitably spaced apart.Such spacing of the cups corresponds to the spacing between each pocket290 of the first in-feed star wheel 284 a. In other words, the in-feedscrew or spacing screw 282 sequentially separates, regaps or spaces thesingle-file cups transported by the conveyor belt 252 to establish aseparation distance that corresponds to the spacing between the pockets290 of the first in-feed star-wheel 284 a. That is, the spacer screw 282delivers, at the correct intervals, each cup into one of the pockets 290of the first in-feed star-wheel 284 a. It should be appreciated that dueto the direction of rotation of the spacer screw 282, a cup may beslightly lifted off the conveyor belt as that cup is transported formthe first end 294 of the spacer screw to the second end 296 of thespacer screw. Accordingly, a hold down member 298, such as a bar made ofany suitable smooth surfaced, non-abrasive material withself-lubrication properties, such as any suitable plastic, for example aDELRIN® plastic manufactured by E. I. DU PONT DE NEMOURS AND COMPANY, issupported by the frame 280 of the cup spacer 210. In this embodiment, ifthe spacer screw lifts the cup off the conveyor belt, the hold downmember 298 engages the bottom of the upside down cup to keep the cup incontact with the threads of the spacer screw. In one embodiment, thespacer screw is movably connected or coupled to at least one actuator288, such as a motor or other suitable movement generating devicecontrolled by the cup reinforcing system processor which causes thespacer screw to rotate in any suitable direction at any suitable speedin a conventional manner.

Each inlet star 284 of the cup spacer 210 is a horizontally orsubstantially horizontally disposed circular or substantially circularmember made of any suitable smooth surfaced, non-abrasive material withself-lubrication properties, such as any suitable plastic, for example aDELRIN® plastic manufactured by E. I. DU PONT DE NEMOURS AND COMPANY.Each inlet star 284 defines a plurality of pockets 290 suitable spacedaround the circumference of that inlet star. The number of pockets isdetermined based on the size of the cups and the size of the reinforcingmembers. Each pocket 290 is configured to hold or otherwise engage a cup102 as the cup is transferred from the cup feeder 208 to the cup moveror turntable 212. Each inlet star is movably connected or coupled to atleast one actuator (not shown), such as a motor or other suitablemovement generating device controlled by the cup reinforcing systemprocessor which causes that inlet star to move in any suitable directionat any suitable speed in a conventional manner.

As illustrated in FIGS. 27A and 28, the frame 280 of the cup spacersupports two inlet star guide members or guide rails 292 a and 292 b(referred to generally as 284). Guide rail 292 a is located adjacent toinlet star 284 a and guide rail 292 b is located adjacent to inlet star284 b. Each guide rail 292 prevents the cups transported by the inletstars 284 from becoming displaced, such as by tipping over. The cupguide members are suitable sized and suitable angled offset from avertical plane to correlate to the cups.

In operation, as best seen in FIGS. 27A and 28, each cup 102 istransported from at or near the second end 296 of the spacer screw 282to a first pocket 290 of the first inlet star 284 a. The first inletstar 284 a transports the cup to a second pocket of the second inletstar 284 b. The second inlet star 284 b transports the cup, along ahorizontally-disposed cup support member 297, to a cup holding station302 of the cup mover 212 as described below. That is, the pockets of thesecond inlet star 284 b and guide rail 292 b co-act to hold a cup in theproper position and place the cup onto one of the cup holding stations302 of the cup mover. It should be appreciated that any suitable meansor manner for transporting one or more cups from the cup dispenser tothe cup mover or turntable may be employed in accordance with the cupreinforcing system disclosed herein.

As seen in FIG. 29, the sidewall of each pocket 290 is angled offsetfrom a vertical plane at a suitable angle to match the angle of thetapered side walls of the cup 102. That is, because even relativelysmall amounts of forces may cause indentions to the outer surfaces ofthe cup 102, each star-wheel pocket 290 is configured to preventdamaging the relatively fragile surface of the base cups. In otherwords, unlike the star-wheel pockets of known bottle labeling machineswhich are designed to transport relatively durable glass bottles, thestar-wheel pockets 290 of the cup spacer 210 of the cup reinforcingsystem disclosed herein is designed to handle the relatively fragileplastic foam cups.

As seen in FIGS. 27A to 31B, the cup mover or turntable 212 of the cupconveyor system is rotatably supported by a suitable frame 300positioned adjacent to the cup spacer 210 and at a height slightly belowthe cup spacer 210. The turntable is a horizontally or substantiallyhorizontally disposed cylindrical or substantially cylindrical membermade of any suitable smooth surfaced, non-abrasive material withself-lubrication properties, such as any suitable plastic, for example aDELRIN® plastic manufactured by E. I. DU PONT DE NEMOURS AND COMPANY.The turntable 212 is movably connected or coupled to at least oneactuator, such as a motor or other suitable movement generating devicewhich causes the turntable to move in any suitable direction at anysuitable speed in a conventional manner. In operation, as describedabove, the cup mover 212 transports each base cup toward the attachmentposition adjacent to a reinforcing member dispenser 204.

The cup mover 212 includes a plurality of individual rotary cup platesor cup holding stations 302 a, 302 b, 302 c and 302 d (referred togenerally as 302) positioned uniformly around the periphery of the cupspacer. Each cup plate or holding station 302 is configured to receive acup 102 from a pocket 290 of the second inlet star 284 b. As describedabove, each cup holding station includes a rotational base 303 operableto rotate a full 360 degrees in clockwise and counterclockwisedirections. In another embodiment, each cup holding station is springloaded and operable to rise to engage the cup transported from the cupspacer and lower to disengage the cup from the cup mover after areinforcing member has been applied to the cup.

Each cup holding station includes a plurality of suitably shaped andsized walls which frictionally engage the walls of the cup to fix thecup in the suitable position on the cup holding station. In operation,as each cup 102 is placed on a cup plate or holding station, the cup isheld in place by a spring biased centering bell 312. Each centering bellis operable to rotate a full 360 degrees in clockwise andcounterclockwise directions. It should be appreciated that any suitablemanner of holding the cup which provides that the tapered side wall ofthe cup is free for application of the reinforcing member may beimplemented in accordance with the cup reinforcing system disclosedherein.

As best seen in FIG. 31B, each centering bell 312 is supported from arotatable superstructure 324. The rotatable superstructure includes acam 326 and a plurality of spring loaded members 328 suitably connectedto the plurality of centering bells 312. The spring loaded members areeach movably connected or coupled to at least one actuator, such as amotor or other suitable movement generating device which causes each ofthe spring loaded members to move in any suitable direction at anysuitable speed in a conventional manner. In operation, as the pluralityof spring loaded members 328 rotate about the cam 326, the shape of thecam causes each spring located member to coil or retract which causeseach centering bell to extend to engage a plurality of the walls of thecup or retract to disengage the plurality of walls of the cup. Thespring mounted pressure of the centering bells engages the cups with atleast enough force to hold the cup as the cup is rotated and with lessforce than would damage the relatively fragile foam cup. It should beappreciated that any suitable mechanism or mechanisms which cause thecentering bells to engage and disengage a plurality of walls of the cupmay be implemented in accordance with the cup reinforcing systemdisclosed herein.

As illustrated in FIGS. 32, 33, 34 and 35, the outer wall of each cupholding station 302 is suitably beveled and tapered to match and engagethe taper of the inner side wall of the top portion of the base cup 102.As best illustrated in FIG. 32, each cup holding station 302 includes avertically disposed sidewall or cup support 304, a horizontally disposedfirst wall 306 connected to the sidewall, a vertically disposed secondwall 308 connected to the first wall and a beveled third wall 310connected to the second wall. The first wall 306 of the cup holdingstation engages the top 330 of the formed lip of the upside down cup andthe second wall 308 of the cup holding station engages a top portion 332of the inner surface of the upside down cup. It should be appreciatedthat any suitable engagement surface which creates a male-femaleconnection between the cup holding station and the cup may beimplemented with the cup reinforcing system disclosed herein.

In one embodiment, to transport the base cup from the cup spacer to thecup holding stations of the turntable, to account for the height of thefrictional engagement members of the holding stations, the turntable ispositioned slightly below the cup spacer. Such positioning of the cupmover below the cup spacer allows each transported cup to be placeddirectly on top of one of the cup holding stations 302 of the cup mover212. That is, to account for the height of the vertically disposedsecond wall 308 of the holding stations 302 when transporting each cup102 from the cup spacer 210 to the cup holding stations 302 of theturntable 212, the turntable is positioned slightly below the cupspacer.

Moreover, the walls of the centering bell are suitably configured tomatch and engage a plurality of the walls of the cup. As bestillustrated in FIGS. 34 and 35, a first wall of the centering bell 314engages the bottom rim 334 of the cup and a beveled or tapered secondwall of the centering bell 316 engages the beveled or tapered inner sidewall 336 of the cup. In this embodiment, a third wall of the centeringbell 318 engages the outer bottom wall 16 of the cup, a fourth wall ofthe centering bell 320 engages the top surface of a centered raisedportion 337 of the outer bottom wall of the cup and a fifth wall of thecentering bell 322 engages the side wall 338 of the centered raisedportion of the outer bottom wall of the cup. It should be appreciatedthat any suitable engagement surface which creates a male-femaleconnection between the centering bell and the cup may be implementedwith the cup reinforcing system disclosed herein.

It should be appreciated that when compared to a turntable of knownbottle labeling devices, the turntable of the cup reinforcing systemincludes a reduced number of holding stations to accommodate the lengthof the reinforcing member. That is, since the reinforcing membersapplied to the base cups are of greater length than the labels appliedto the bottles of a bottle labeling machine and such greater length maycause interferences when the reinforcing member is partially attached tothe cups as described below, a greater distance must be between eachholding station/centering bell of the turntable. Accordingly, providinga greater distance between each holding station/centering bell of theturntable without increasing the size of the turntable requires areduction in the number of holding stations/centering bells of theturntable.

As described above and best illustrated in FIGS. 42A to 43F, the frameof the cup mover 212 supports a plurality of reinforcing memberapplication pads 390 a and 390 b (referred to generally as 390). Eachreinforcing member application pad 390 includes a base 392 a and 392 b(referred to generally as 392) and a reinforcing member engaging surface394 a and 394 b (referred to generally as 394), wherein the reinforcingmember engaging surface includes any suitable material withanti-adhesion properties, such as a polytetrafluoroethylene or Teflon®coated tape, which resists adherence by the adhesive coated on thereinforcing member. Each reinforcing member application pad 390 ispositioned relative to the reinforcing member point of attachment toprovide a suitable surface which is engaged by the tapered side wall ofthe cup to secure the reinforcing member (which is positioned betweenthe tapered side wall of the cup 102 and the engaging surface 394 of thereinforcing member application pad 390) to the tapered side wall of thecup. Each reinforcing member application pad 390 is suitably shaped andsized to accommodate the size and shape of the cups which are reinforcedas well as to accommodate the size of the cup mover 212 which is movingthe cups. For example, each reinforcing member application pad 390 issuitably beveled and tapered to match and engage the tapered side wallof the cup. It should be appreciated that the height or angle of one ormore reinforcing member application pads may be suitable adjusted toaccommodate the shape and size of the cups.

As described above, the cup mover 212 is configured to transport eachbase cup into a reinforcing member point of attachment or engagement orattachment position. At this point of attachment, a reinforcing member,dispensed from the reinforcing member dispenser 204 described below, issuitable partially attached to the tapered side wall of the cup 102.

After a reinforcing member is attached to a cup 102, the cup mover 212transports each reinforced cup to a cup remover 214. As illustrated inFIG. 37, the cup remover 214 of the cup conveyor system includes a frame340 positioned adjacent to and at substantially the same height as thecup mover 212. The frame 280 of the cup feeder supports two co-actinginlet stars or in-feed star-wheel conveyors 342 a and 342 b (referred togenerally as 342), an out-feed conveyor device 344 and a reinforced cupexhaust device 346. In one embodiment, the cup reinforcing systemincludes one outlet star or out-feed star-wheel which transports thecups from the cup mover to the out-feed reinforced cup conveyor device.In one embodiment (not shown), the cup reinforcing system utilized oneor more brushes to engage the sidewall of each cup to enhance themovement of each cup from the turntable of the cup mover to the out-feedreinforced cup conveyor device. Each outlet star 342 is movablyconnected or coupled to at least one actuator, such as motor or othersuitable movement generating device controlled by the cup reinforcingsystem processor which causes the outlet star to rotate or move in anysuitable direction at any suitable speed in a conventional manner.Similar to the inlet stars described above, each outlet star 342includes a plurality of pockets 346 on its circumference. Each pocket346 is configured to hold a cup 102 as the cup is transferred from thecup mover 212. The sidewall of each pocket 246 is angled offset from avertical plane at a suitable angle to match the angle of the taperedside walls of the base cups.

The frame 340 of the cup remover 212 supports two outlet star guidemembers or guide rails 348 a and 348 b (referred to generally as 348).Guide member 348 a is located adjacent to outlet star 342 a and guidemember 348 b is located adjacent to outlet star 342 b. Each guide member348 prevents the cups transported by their respective outlet star 342from becoming displaced, such as by tipping over. The cup guide members348 are sized and angled offset from a vertical plane to correlate tothe specifications of the reinforced cups. In another embodiment, thecup reinforcing system includes a plurality of inlet stars or in-feedstar-wheels which co-act to transport the cup from the cup mover 212 tothe out-feed cup conveyor device 344.

The out-feed cup conveyor device 344 is suitably movably connected orcoupled to at least one actuator, such as a motor or other suitablemovement generating device which causes the conveyor belts to move atany suitable speed in a conventional manner. The cup remover includes atleast two opposing spaced-apart elongated guide rails or guide tracks350 supported by the frame 340 of the cup remover. The guide rails 350are angled offset from a vertical plane at a suitable angle to match theangle of the tapered side walls of the cups transported by the out-feedcup conveyor device 344.

As seen in FIG. 37, each cup 102 is transported, via the out-feedreinforced cup conveyor device 344, to a cup positioner 352, such as acup tipper or other suitable member, which positions or tips thereinforced cup onto its side (downside leading). The guide rails 350insure that the tipped cup is positioned on its side. The tipped cup isthen vacuum pulled via the cup exhaust system 346 (not shown) to a stackof nested reinforced cups. It should be appreciated that any suitablemeans or manner for transporting one or more cups from the cup dispenserto the cup mover or turntable may be employed in accordance with the cupreinforcing system disclosed herein.

In one embodiment, as illustrated in FIGS. 38A, 38B, 39 and 40, eachreinforcing member dispenser 204 of the cup reinforcing system includesa frame 360 which supports an adjustable base or support 386. Asdescribed above, the reinforcing member dispenser 204 is operable tofeed each reinforcing member 42 toward a cup 102 at a suitable angleoffset form a vertical plane which corresponds with the angle (alsooffset from a vertical plane) of the tapered side wall of the cup.Accordingly, the adjustable base 386 of the reinforcing member dispenser204 is suitably angled offset from a vertical plane. The angle which theadjustable base 386 of the reinforcing member dispenser 204 is at may beadjusted (via a suitable angle adjustment mechanism 382) to accommodatefor different base cups with different angled tapered side walls.

In addition to adjusting the angle of the reinforcing member dispenseroffset from a vertical plane, the height of the adjustable base 386 ofthe reinforcing member dispenser 204 may be adjusted (via a suitableheight adjustment mechanism 384) to accommodate for different sized cupsand variances in different reinforcing members positioning on the liner.Moreover, the angle which the adjustable base 386 of the reinforcingmember dispenser 204 is at may be adjusted offset from a horizontalplane if necessary. Accordingly, it should be appreciated that thereinforcing member dispenser may be individually adjusted in threeseparate planes to facilitate a proper attachment of a reinforcingmember to the tapered sidewall of a cup. In alternative embodiments, thereinforcing member dispenser may be adjusted to any suitable angle inany suitable plane or number of planes to facilitate a proper attachmentof a reinforcing member to the tapered sidewall of a cup.

The reinforcing member dispenser includes two reinforcing member supplyholders 362 a and 362 b (referred to generally as 362) supported by theadjustable base 386. Each reinforcing member supply holder 362 isconfigured to hold a supply 364 a and 364 b (referred to generally as364) of reinforcing members, wherein each supply of reinforcing membersincludes a plurality of reinforcing members sequentially releasablyattached to an elongated release liner (as best seen in FIGS. 7 and 7A)wound about a central cylindrical tube 388 a and 388 b (referred togenerally as 388) into a roll. Each reinforcing member dispenserincludes at least one and preferably a plurality of drive rollers, suchas drive rollers 366 a and 366 b (referred to generally as 366)supported by the adjustable base 386 and configured to drive or pull therelease liner 56 (which the reinforcing members are releasably attachedto). In operation, drive roller 366 a pulls or drives the release liner56 from the supply roll toward drive roller 366 a and into a designatedarea 374 of a release liner slack accumulator 372 (as described below).Drive roller 366 b then pulls or drives the release liner from thedesignated area 374 of the release liner slack accumulator 372 andtowards the cup-reinforcing member point of attachment or engagement.Each drive roller 366 is suitably movably connected or coupled to atleast one actuator (not shown), such as a motor or other suitablemovement generating device which causes the drive rollers to move at anysuitable speed. In one embodiment, one, more or each of the driverollers 366 includes a knurled surface to better engage the releaseliner as it is fed through the reinforcing member dispenser. In anotherembodiment, one, more or each of the drive rollers 366 includes a rubbersurface to better engage the release liner as it is fed through thereinforcing member dispenser.

Each reinforcing member dispenser includes a powered take-up roller 367,supported by the adjustable base 386 and configured to pull or drive theused release liner 56 to a liner accumulation holder 376. The poweredtake-up roller 367 is suitably movably connected or coupled to at leastone actuator (not shown), such as a motor or other suitable movementgenerating device which causes the take-up roller to move at anysuitable speed.

Each reinforcing member dispenser also includes a plurality of guidesand tensioners, such as guide rollers 368, supported by the adjustablebase 386 and configured to guide the release liner (which thereinforcing members are releasably attached to) toward the point ofengagement with the cups as well as maintain suitable amounts of tensionon the release liner.

The reinforcing member dispenser 204 includes a vertically disposedrelease liner splicer 370 supported by the adjustable base 386 andconfigured to allow a plurality of supplies of reinforcing members to bespliced together. The release liner splicer 370 includes a first area(not shown) configured for holding the trailing end of a first releaseliner supply and a second area (not shown) for holding the leading endof a second release liner supply. The release liner splicer provides amechanism for a user of the cup reinforcing system to splice thetrailing end of the first release liner supply to the leading end of thesecond release liner supply to insure that the reinforcing memberdispenser is provided a continuous supply of release liner.

For example, in one embodiment, when the last reinforcing member of thefirst release liner supply is detected, a user centers the first releaseliner supply over a cutting groove and utilizes one or more suitablemechanisms to hold the first release liner supply in place. The userthen slides the second release liner supply over the first release linersupply, places the leading edge of the first reinforcing member of thesecond release liner supply exactly over the last reinforcing member ofthe first release liner supply and utilizes one or more suitablemechanisms to hold the second release liner supply in place. The userutilizes a suitable cutting head and cutting guide to cut the first andsecond release liner supplies, removes the scrap pieces from the firstand second release liner supplies and tapes the first and second releaseliner supplies together.

As seen in FIG. 38A, the reinforcing member dispenser 204 also includesa release liner slack accumulator 372 a supported by the adjustable base386 and configured to provide a designated area 374 a where slack in therelease liner may accumulate. As seen in FIG. 38B, in an alternativeembodiment, the reinforcing member dispenser 204 includes analternatively designed release liner slack accumulator 372 b supportedby the adjustable base 386 and configured to provide an alternativelydesigned designated area 374 b where slack in the release liner mayaccumulate. In one embodiment (not shown), the release liner slackaccumulator includes one or more debris removes supported by theadjustable base and configured to remove any debris, such as dust orpowder, from the back side of the release liner as the release liner isfed into and/or out from the designated area where slack in the releaseliner may accumulate. The reinforcing member dispenser 204 also includea liner accumulation holder 376 supported by the adjustable base 386 andconfigured to hold the release liner after separation from thereinforcing members.

As seen in FIGS. 42B and 43A to 43F, the reinforcing member dispenser204 also includes at least one sensor 378 supported by the adjustablebase 386 and configured for determining the location of a reinforcingmember 42. It should be appreciated that the height and position of thesensor 378 may be adjusted depending on the configuration of the cupswhich are being reinforced. In one embodiment, the reinforcing memberdispenser also includes one or more sensors (not shown) supported by theadjustable base and configured for determining the position and amountof release liner which has accumulated in the designated area of therelease liner slack accumulator. The reinforcing member dispenser 204includes a release liner separator 380, such as a separation plate,supported by the adjustable base 386 and configured for separating thereinforcing members from the release liner.

Each reinforcing member supply holder 362 is configured to hold a woundsupply roll of liner 56 (which the plurality of reinforcing members arereleaseably attached to). In one embodiment, each roll of woundreinforcing members are held in a horizontal configuration. In thisembodiment, as the reinforcing members are held in the sameconfiguration which they will be applied to the base cups, it is notnecessary to reconfigure or otherwise twist the reinforcing membersprior to application to the cups. In another embodiment, each roll ofwound reinforcing members are held in a vertical configuration. In thisembodiment, the reinforcing members must be reconfigured or twistedprior to application to the base cups.

In one embodiment, the plurality of guide rollers 368 of the reinforcingmember dispenser 204 are designed to feed the liner 56 from the linersupply roll 364, past the liner splicer 370, through the release linerslack accumulator 372, past the sensor 378 and the release linerseparator 380 and to the roll of used liner 376. In one embodiment, one,more or each of the guide rollers 368 includes a knurled surface tobetter engage the release liner as it is fed through the reinforcingmember dispenser. In another embodiment, one, more or each of the guiderollers 368 includes a rubber surface to better engage the release lineras it is fed through the reinforcing member dispenser. It should beappreciated that the rollers are of suitable height to accommodate thesize of the release liner (and the attached reinforcing members) whichare engaged by the plurality of rollers.

As best illustrated in FIGS. 39 and 40, the release liner slackaccumulator 372 is an elongated substantially unshaped member whichprovides a designated area 374 wherein slack in the liner 56 mayaccumulate. That is, due to the need to accurately apply the reinforcingmembers to the tapered side wall of the cup along the centered verticalaxis of the reinforcing member, the processor of the cup reinforcingsystem often must adjust the speed which the reinforcing members aremoving to insure that the cups moving on the turntable and thereinforcing members dispensed by the reinforcing dispenser come intocontact at the appropriate time and location such that the centeredvertical axis of the reinforcing member is applied to the cup on aconsistent basis with a range of error of less than plus or minus 0.1inches. In other words, providing an area where slack can accumulateenables the processor of the cup reinforcing system to adjust the speedat which the liner is fed through the reinforcing member dispenserwithout otherwise affecting the feed of the release liner from thesupply of release liner. For example, the designated area of the releaseliner slack accumulator is operable to accommodate the length of releaseliner which five to six reinforcing members are releasably attached to.It should be appreciated that the release liner slack accumulatorassociated with the cup reinforcing system disclosed herein is longerand more narrow than the release liner slack accumulators of knownbottle labeling systems to accommodate for the increased length of thereinforcing members applied to the base cups.

As described above, the sensor 378 of each reinforcing member dispenser204 is utilized for determining or verifying the location or position ofthe reinforcing member 42 relative to the position of the cup 102. Thesensor may be any suitable sensor, including but not limited to opticalsensors or ultrasonic sensors. In operation, the sensor 378 detects thelocation of the substantially vertical portion of the front or leadingedge 70 of the reinforcing member 42 to determine the relative positionof the reinforcing member. Based on this determined position of thereinforcing member and any other suitable information (such as the speedthe cup is moving, the speed the reinforcing member is being fed throughthe reinforcing member dispenser, the length of the reinforcing memberand the diameter of the cup), the processor 402 of the cup reinforcingsystem determines or calculates when the reinforcing member is movedinto a position in which the centered vertical axis of the reinforcingmember is aligned with the tapered side wall of the base cup.

As best illustrated in FIG. 42B, the sensor 378 is positioned or placedsuch that the sensor detects the relative location of each reinforcingmember immediately prior to that reinforcing member being affixed to abase cup. In this embodiment, positioning the sensor at such a locationprovides for increased accuracy in the placement of the reinforcingmember on the base cup which provides for a proper engagement betweenthe reinforcing member and the cup. It should be appreciated that in abottle labeling machine, since the labels first engage the bottles atthe labels leading edge, accuracy in attaching the labels at a specificposition of the label is sacrificed to increase the speed which thelabels are attached. Accordingly, the sensor in known bottle labelingmachines is placed at a position substantially upstream from where thelabels are attached to the bottles. On the other hand, in the cupreinforcing system disclosed herein, since the reinforcing members mustbe attached to the tapered side wall of the base cup not by the leadingedge but at a specific position along the centered vertical axis, thesensor is placed adjacent to where the reinforcing member will engagethe base cup to increase the accuracy in attaching the reinforcingmember at a specific position. In this embodiment, the cup reinforcingsystem disclosed herein sacrifices the speed which the cups may bereinforced in exchange for increased accuracy in the properreinforcement of such cups and specifically the proper positioning ofthe attachment of the reinforcing members to the tapered side walls ofthe cups.

The release liner separator 380, such as a separation plate, of eachreinforcing member dispenser 204 is configured to separate thereinforcing members 42 from the release liner 56. That is, based on theorientation of the reinforcing member 42 relative to the release linerseparator, the reinforcing members will separate from the release liner(which protects the pressure sensitive adhesive) when the reinforcingmembers are fed, via the release liner, through the release linerseparator 380. It should be appreciated that since the reinforcingmembers are toward the base cups at a suitable angle offset form avertical plane which corresponds with the angle (also offset from avertical plane) of the tapered side wall of the base cup, the releaseliner separator 380 is also suitably angled offset from a verticalplane.

The liner accumulation holder 376 is configured to accumulate andsuitably wind the release liner after the reinforcing members areseparated from the release liner. In one embodiment, after the releaseliner passes the reinforcing member point of attachment or point ofengagement, the release liner is fed, via one or more suitable rollers,to the release liner accumulation holder. In one embodiment, the lineraccumulation holder is movably connected or coupled to one or moreactuators (or other suitable movement generating devices controlled bythe cup reinforcing system processor) which causes the lineraccumulation holder 376 to rotate or move in any suitable direction atany suitable speed. In different embodiments, each wound roll of usedrelease liner is held in a horizontal configuration or in a verticalconfiguration.

As seen in FIG. 18A, the cup reinforcing system disclosed herein maysequentially utilize a plurality of cup reinforcing dispensers 204 a and204 b. In operation, while a first cup reinforcing dispenser 204 a isapplying or attaching a plurality of reinforcing members 42 to aplurality of cups 102, a second cup reinforcing dispenser 204 b is beingsuitably prepared (i.e., part of the wound roll of liner is fed, via therollers, through the entire cup reinforcing dispense) to also apply orattach reinforcing members. Accordingly, when the supply of reinforcingmembers of the first cup reinforcing dispenser 204 a is exhausted, thesecond cup reinforcing dispenser 204 b begins applying or attaching aplurality of reinforcing members to a plurality of base cups withminimal delay.

As seen in FIG. 41A to 41D, in various alternative embodiments, aplurality of reinforcing member dispensers 204 a, 204 b and 204 c areoperable to sequentially reinforce each cup 102. In this embodiment, afirst reinforcing member is applied to a base cup by a first reinforcingmember dispenser followed by the application of a second reinforcingmember by a second reinforcing member dispenser. For example, the firstreinforcing member dispenser 204 a applies a first reinforcing member toa base cup at a first point of engagement on the cup mover and at asecond, downstream point of engagement, a second reinforcing member isapplied by a second reinforcing member dispenser 204 b or 204 c. Itshould be appreciated that in this embodiment, any suitable number ofreinforcing member dispensers 204 may be implemented in accordance withthe cup reinforcing system disclosed herein.

It should be appreciated that any suitable configuration of the cupreinforcing system and specifically any suitable design of the cupconveyor system relative to one or more reinforcing member dispensersmay be utilized to attach a reinforcing member to a base cup asdescribed above. For example, FIG. 41A illustrates the configuration ofthe cup conveyor illustrated in FIGS. 18A and 18B with three reinforcingmember dispensers. FIG. 41B illustrates another embodiment wherein thecup spacer and cup remover each utilize one star-wheel and the cupsenter and exit the cup reinforcing system through opposite ends. FIG.41C illustrates another embodiment wherein the cup spacer utilizes twostar-wheels, the cup remover utilizes one star-wheel and the cups enterand exit the cup reinforcing system through the same end. FIG. 41Dillustrates another embodiment wherein the cup spacer utilizes aplurality of star-wheels, the cup remover utilizes one star-wheel andthe cups enter and exit the cup reinforcing system through differentends.

In an alternative embodiment, as illustrated in FIGS. 42A and 43A, afirst base or pre-reinforced cup 102 a is moved into an attachmentposition and the reinforcing member dispenser 204 dispenses a firstreinforcing member 42 a. As seen in FIGS. 42B and 43B, the reinforcingmember engages the tapered side wall of the base cup. As describedabove, the first reinforcing member 42 a engages the tapered side wallof the first base cup 102 a at an angle offset from a vertical planewhich corresponds to the angle of the tapered side wall of the base cup.

As illustrated in FIG. 43C, after the first reinforcing member 42 aengages the first base cup 102 a, in one embodiment, the first cup 102 ais moved, via the cup mover 212, downstream from the point of engagementor attachment of the reinforcing member. In this embodiment, since thefirst reinforcing member 42 a is attached, along a centered verticalplane, to the tapered side wall of the first base cup 102 a, as the cupis moved away from the point of engagement, any remaining portion of thefirst reinforcing member 42 a which is attached to the release liner isseparated from the release liner 56.

As illustrated in FIGS. 42C and 43D, after the first cup 102 a and firstreinforcing member 42 a are moved downstream from the point ofengagement to completely separate the first reinforcing member 42 a fromthe release liner 56, in one embodiment, the first base cup 102 a isrotated 10 degrees to 20 degrees in a first, clockwise direction toattach a first, centered portion of the first reinforcing member 42 a tothe cup. In this embodiment, the rotation of the base cup causes aportion of the reinforcing member and the base cup to engage areinforcing member application pad 390 a, such that the tapered sidewall of the cup presses against or engages the reinforcing memberengaging surface 394 a of the application pad 390 a to cause the first,centered portion of the first reinforcing member 42 a (which ispositioned between the tapered side wall and the reinforcing memberapplication pad 390 a) to engage with and adhere to the tapered sidewall of the first cup 102 a.

It should be appreciated that this first rotation of 10 degrees to 20degrees reduces the length of the unattached reinforcing member andreduces the possibility that at least one of the edges of thereinforcing member from the first cup will interfere with the attachmentof a reinforcing member to a second, subsequently reinforced cup.Moreover, such a first rotation further secures the reinforcing memberto the base cup by providing that an area of the reinforcing membergreater than the centered vertical axis of the reinforcing member isattached to the base cup. In another embodiment, the reinforcing memberis attached to the cup without such a first rotation of 10 degrees to 20degrees. It should be further appreciated that when the reinforcingmember is initially attached to the cup, the sensing edge 70 is: (i)perpendicular or substantially perpendicular to the bottom edge of thecup; and (ii) parallel to the centered vertical axis of the reinforcingmember. Such a configuration provides an absolute reference point forthe cup reinforcing system to determine the location of the reinforcingmember.

As illustrated in FIGS. 42D and 43E, in one embodiment, the firstrotation of the cup is followed by a second, counter-clockwise rotationgreater than 180 degrees to attach a second, trailing edge portion ofthe first reinforcing member 42 a to the first cup 102 a. In thisembodiment, the rotation of the base cup causes a portion of thereinforcing member 42 a and the cup 102 a to engage a reinforcing memberapplication pad 390 a, such that the tapered side wall of the cuppresses against or engages the reinforcing member engaging surface 394 aof the application pad 390 a to cause the second, trailing edge portionof the first reinforcing member 42 a (which is positioned between thetapered side wall and the reinforcing member application pad 390 a) toengage with and adhere to the tapered side wall of the first cup 102 a.

As seen in FIGS. 42E and 43F, in one embodiment, the second rotation isfollowed by rotating the cup a third, clockwise rotation greater than360 degrees to attach a third, leading edge portion of the firstreinforcing member 42 a to the first cup 102 a. In this embodiment, therotation of the base cup causes a portion of the reinforcing member 42 aand the cup 102 a to engage a reinforcing member application pad 390 b,such that the tapered side wall of the cup presses against or engagesthe reinforcing member engaging surface 394 b of the application pad 390b to cause the third, leading edge portion of the first reinforcingmember 42 a (which is positioned between the tapered side wall and thereinforcing member application pad 390 a) to engage with and adhere tothe tapered side wall of the first cup 102 a.

It should be appreciated that as described above, the cup reinforcingsystem disclosed herein is operable to sequentially reinforce aplurality of cups. As best seen in FIGS. 42D, 42E, 43E and 43F, afterthe first cup 102 a and first reinforcing member 42 a moved downstreamfrom the point of engagement, a second cup 102 b and a secondreinforcing member 42 b are moved into an appropriate attachmentposition.

In another embodiment, one or more reinforcing member application padsare movable and suitably operable to attach, either sequentially orsimultaneously, the remaining free portions of the reinforcing member tothe tapered side wall of the cup. In this embodiment, the cup is keptsubstantially stationary or stationary and the reinforcing memberattachment pads rotate or move to attach the reinforcing member to thetapered sidewall of the cup.

In another embodiment (not shown), the reinforcing member is initiallyattached to the tapered sidewall of the cup not along the centeredvertical axis of the reinforcing member. In this embodiment, thereinforcing member is applied along an off-centered vertical axis of thereinforcing member and the methods described above are suitably modifiedto compensate for the off-centered point of attachment. In anotherembodiment (not shown), the reinforcing member is initially attached tothe tapered sidewall of the cup along the leading edge of thereinforcing member. Accordingly, it should be appreciated that anysuitable method and apparatus operable to target or attach a specificspot or location on the reinforcing member to a specific spot orlocation on the cup may be utilized in the cup reinforcing systemdisclosed herein.

In one alternative embodiment, as illustrated in FIGS. 44A to 44D, oneside of the reinforcing members are not completely or substantiallycompletely coated with an adhesive. In this embodiment, as describedabove, the cups are placed on cup holding stations of the cup mover 212and transported to different areas of the cup reinforcing system. Asbest seen in FIG. 44A, the cup reinforcing system includes an adhesiveapplication device 420. In operation, when a suitable sensor 378 adetects the appropriate position of a cup 102, the adhesive applicationdevice 420 applies a suitable adhesive directly to the surface of thetapered side walls of the base cup. In one embodiment, the adhesive isapplied or sprayed onto the surface of the tapered side wall of the basecup as a mist or atomized spray. It should be appreciated that theadhesive may be applied using other suitable processes such as dippingthe base cup into a container of the adhesive.

In one such embodiment, as best seen in FIG. 44B, after the tapered sidewalls of the base cup are completely or substantially completely coatedwith an adhesive and a suitable sensor 378 b detects the appropriateposition of the cup, a reinforcing member 42 is attached to the basecup. In this embodiment, since one side of the reinforcing members arenot coated with an adhesive, the reinforcing members do not need to bestored along a release liner and may be stored as a stack of reinforcingmembers 422. Accordingly, in this embodiment, a suitable reinforcingmember holding device or mechanism 424 dispenses the non-adhesive backedreinforcing members, one at a time, to engage the tapered side wall ofthe base cups. The reinforcing member holding device 424 includessuitably spaced apart sidewalls 426 a and 426 b which support the stackof reinforcing members. The reinforcing member holding device may beconnected or coupled to at least one actuator, such as a motor, aspring-loaded mechanism or other suitable movement generating devicecontrolled by the cup reinforcing system processor which causes thereinforcing member holding device to move into a suitable position suchthat a held reinforcing member engages an adhesive coated cup. In analternative embodiment, the adhesive is suitably sprayed onto anapplicator which applies the adhesive to the sidewall of the cup. Inanother embodiment, the adhesive is suitably sprayed onto an applicatorwhich applies the adhesive to one of the surfaces of the reinforcingmember. As described above, in these alternative embodiments, thereinforcing member is situated at an angle which corresponds with theangle of the tapered side wall of the cup and thus the reinforcingmember is attached to the base cup at an angle which corresponds withthe angle of the wall of the base cup. Moreover, as described above, inthese alternative embodiments, the reinforcing member must initiallyengage the base cup along the centered vertical axis of the base cup.

As best illustrated in FIG. 44C, after the reinforcing member 42 isattached to the tapered side wall of the cup 102 along the centeredvertical axis 108 of the reinforcing member, this embodiment of the cupreinforcing system is operable to cause the remaining unattachedportions of the reinforcing member to engage and attach to the taperedside wall of the cup. In one embodiment, utilizing the cup holdingstation on which the cup resides, the cup rotates 180 degrees in a firstdirection. As the cup is rotating, the tapered side wall of the cuppresses against or engages a reinforcing member engaging surface 394 ofa reinforcing member application pad 390 to cause a first portion orsection of the reinforcing member to engage and attach, due to theadhesive coating applied to the sidewall of the cup, to the tapered sidewall of the cup. In one embodiment, the first portion or sectionincludes the portion of the reinforcing member which extends from thecentered vertical axis to the trailing edge.

As best seen in FIG. 44D, in one embodiment, following a rotation of thecup in a first direction, the cup is then rotated 360 degrees in anopposite, second direction. As the cup is rotating, the tapered sidewall of the cup presses against or engages the reinforcing memberengaging surface 394 of the reinforcing member application pad 390 tocause the second portion or section of the reinforcing member to engageand attach to the tapered side wall of the cup. In one embodiment, thesecond portion or section includes the portion of the reinforcing memberwhich extends from the centered vertical axis to the leading edge. Itshould be appreciated that this embodiment of the cup reinforcing systemis operable to sequentially reinforce a plurality of cups. For example,a first reinforcing member from the stack of reinforcing members engagesa first adhesive coated cup followed by a second reinforcing member fromthe stack of reinforcing members engaging a second adhesive coated cup.

In another alternative embodiment, the structure of the cup reinforcingsystem illustrated in FIGS. 18A and 18B is suitably reversed. That is,rather than the cup mover 212 rotating in a counter-clockwise direction,the cup mover rotates in a clockwise direction. It should be appreciatedthat in this embodiment, the individual rotations of each cup holdingstation would be modified to accommodate for the change in direction ofthe cup mover. In other words, each cup holding station would rotateeach individual cup 15 degrees to 20 degrees in a first,counter-clockwise direction, followed by a second, clockwise rotationgreater than 180 degrees and followed by a third, counter-clockwiserotation greater than 360 degrees.

It should be appreciated that the methods and apparatus described abovemay also be utilized to apply a reinforcing member or otherwise suitablywrap any other container or receptacle, such as a bowl, a bottle, acarton, a dish, a jar, a mug, or a pitcher. It should be furtherappreciated that the methods and apparatus described above may also beutilized to apply a reinforcing member or otherwise suitably wrap anon-plastic foam container, such as a paper container or another type ofplastic container.

Accordingly, in one embodiment, the cup reinforcing system disclosedherein produces a reinforced plastic foam cup including a plastic foamconical body, and a flat reinforcing member affixed around the outersurface of the tapered side wall in an overlapping manner. The plasticfoam conical body defines an open top end, a closed bottom end, and atapered side wall extending from the bottom end to the top end, whereinthe top end includes an outwardly rolled lip, the top end has a greaterdiameter than the bottom end and the tapered side wall having an outersurface and an inner surface. The flat reinforcing member includes arigid material layer having an inner surface and an outer surface, and apressure sensitive adhesive layer which covers substantially the entireinner surface of the material layer. Prior to being affixed around theouter surface of the tapered side wall, the reinforcing member has aconcave or first edge and a convex or second edge, wherein a trough ofthe concave edge is aligned in a same plane as an apex of the convexedge. The pre-affixed reinforcing member includes a leading or thirdedge and a sensing or fourth edge, the leading edge and sensing edgeextending between the concave and convex edges at one end of thematerial layer. The pre-affixed reinforcing member also includes atrailing or fifth edge and an adhesive relief or sixth edge, thetrailing edge and adhesive relief edge extending between the concave andconvex edges at an opposite end of the material layer, the leading edgeand trailing edge extending in intersecting planes, the sensing edge andadhesive relief edge extending in substantially parallel planes. Afterbeing affixed around the outer surface of the tapered side wall, theconcave edge is adjacent to the closed bottom end of the plastic foamconical body, the convex edge is adjacent to the open top end of theplastic foam conical body, the leading edge and trailing edge extend insubstantially parallel planes, and the sensing edge and adhesive reliefedge extend in intersecting planes.

In another embodiment, the cup reinforcing system produces a reinforcedplastic foam cup, the reinforced cup including a plastic foam cup and areinforcing member affixed around the outer surface of the tapered sidewall in an overlapping manner. The plastic foam cup includes a bottomwall, and a conical shaped side wall integrally formed at one end withthe bottom wall and extending from the bottom wall to a top end, theside wall having an inner surface and an outer surface, the bottom walland side wall defining a cavity, the top end defining an opening for thecavity, the top end having a greater diameter than the bottom end. Theplastic foam cup also includes an outwardly extending lip integrallyformed with the top end of the side, and a downwardly extending lipintegrally formed with the side wall and extending below the bottomwall. The reinforcing member includes a paper material layer having aninner surface and an outer surface, and a pressure sensitive adhesivelayer which covers substantially the entire inner surface of the papermaterial layer. Prior to being affixed around the outer surface of theside wall, the reinforcing member has a concave or first edge, and aconvex or second edge, wherein a trough of the concave edge is alignedin a same plane as an apex of the convex edge. The pre-affixedreinforcing member includes a leading or third edge, and a sensing orfourth edge, the leading edge and sensing edge extending between theconcave and convex edges at one end of the material layer. Thepre-affixed reinforcing member also includes a trailing or fifth edge,and an adhesive relief or sixth edge, the trailing edge and adhesiverelief edge extending between the concave and convex edges at anopposite end of the material layer, the leading edge and trailing edgeextending in intersecting planes, the sensing edge and the adhesiverelief edge extending in substantially parallel planes. After beingaffixed around the outer surface of the side wall the concave edge isadjacent to a bottom edge of the downwardly extending lip, the convexedge is adjacent to the outwardly extending lip, the leading edge andtrailing edge extend in substantially parallel planes, and the sensingedge and adhesive relief edge extend in intersecting planes.

In another embodiment, the cup reinforcing system disclosed hereinincludes a plastic foam cup reinforcing member supply roll whichincludes an elongated backing strip and a plurality of flat reinforcingmembers sequentially aligned along the elongated backing strip. Eachreinforcing member including a paper material layer having an innersurface and an outer surface. Each reinforcing member has a concave orfirst edge, and a convex or second edge, wherein a trough of the concaveedge is aligned in a same plane as an apex of the convex edge. Eachreinforcing member has a leading or third edge, and a sensing or fourthedge, the leading edge and sensing edge extending between the concaveand convex edges at one end of the material layer. Each reinforcingmember also has a trailing or fifth edge, and an adhesive relief orsixth edge, the trailing edge and adhesive relief edge extending betweenthe concave edge and convex edge at an opposite end of the materiallayer, the leading edge and trailing edge extending in intersectingplanes, the sensing edge and adhesive relief edge extending insubstantially parallel planes. Each reinforcing member configured suchthat when the reinforcing member is affixed around an outer surface of atapered side wall of a conical cup having a bottom end and a top end,wherein the top end has a diameter greater than the diameter of thebottom end, the concave edge is adjacent to the bottom end of theconical cup, the convex edge is adjacent to the top end of the conicalcup, the leading edge and trailing edge extend in substantially parallelplanes, and the sensing edge and adhesive relief edge extend inintersecting planes. Moreover, each the reinforcing member affixed tothe backing strip by a pressure sensitive adhesive layer which coverssubstantially the entire inner surface of the paper material layer.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the present invention andwithout diminishing its intended advantages. It is therefore intendedthat such changes and modifications be covered by the appended claims.

1. A method of reinforcing a plastic foam cup, said method comprising:(a) molding a plastic foam conical body which has: (i) an open top endincluding an outwardly rolled lip, the open top end having a firstdiameter of a first length, (ii) a closed bottom end having a seconddiameter of a second length, wherein the length of the second diameteris less than the length of the first diameter, and (iii) a tapered wallextending from the bottom end to the top end, said tapered wall havingan outer surface and an inner surface; (b) providing a flat reinforcingmember having: (i) a rigid material layer having an inner surface and anouter surface, (ii) a pressure sensitive adhesive layer which coverssubstantially the entire inner surface of the material layer, (iii) aconcave edge, (iv) a convex edge, wherein a trough of the concave edgeis aligned in a same plane as an apex of the convex edge, (v) a leadingedge; and (vi) a trailing edge, said leading edge and trailing edgeextending in intersecting planes, wherein a length between the leadingedge and the trailing edge adjacent to the concave edge is less than thefirst length of the first diameter of the open top end of the plasticfoam conical body and a length between the leading edge and the trailingedge adjacent to the convex edge is less than the second length of thesecond diameter of the closed bottom end of the plastic foam conicalbody, (c) at a point during the shrinking of the molded plastic foamconical body, affixing the outer surface of the flat reinforcing memberaround the tapered wall of the plastic foam conical body such that: (i)the concave edge is adjacent to the closed bottom end of the plasticfoam conical body, (ii) the convex edge is adjacent to the open top endof the plastic foam conical body, (iii) the leading edge and trailingedge extend in substantially parallel planes, and (iv) the leading edgeand trailing edge define a first gap having a first gap width; and (d)allowing the molded plastic foam conical body to further shrink, whereinafter the molded plastic foam conical body has further shrunk, theleading edge and trailing edge of the affixed reinforcing member definea second gap having a second gap width, the second gap width being lessthan the first gap width.
 2. The method of reinforcing a plastic foamcup of claim 1, which includes graphics on the reinforcing member. 3.The method of reinforcing a plastic foam cup of claim 1, which includesgraphics printed on the outer surface of the rigid material layer. 4.The method of reinforcing a plastic foam cup of claim 1, wherein priorto being affixed around the tapered wall of the plastic foam conicalbody, the flat reinforcing member includes a sensing edge and anadhesive relief edge, said leading edge and sensing edge extendingbetween the concave and convex edges at one end of the material layer,said trailing edge and adhesive relief edge extending between theconcave and convex edges at an opposite end of the material layer, andsaid sensing edge and adhesive relief edge extending in substantiallyparallel planes.
 5. The method of reinforcing a plastic foam cup ofclaim 4, wherein after affixing the outer surface of the flatreinforcing member around the tapered wall of the plastic foam conicalbody, the sensing edge and adhesive relief edge extend in intersectingplanes.
 6. A method of manufacturing a reinforced plastic foam cup, saidmethod comprising: (a) molding a plastic foam cup having: (i) a bottomend, (ii) a conical shaped side wall integrally formed at one end withthe bottom wall and extending from the bottom wall to a top end, (iii)said side wall having an inner surface and an outer surface, said bottomwall and side wall defining a cavity, (iv) said top end defining anopening for the cavity, (v) said top end having a first diameter of afirst length; (vi) said bottom end having a second diameter of a secondlength, wherein the second length of the second diameter is less thanthe first length of the first diameter, (vi) an outwardly extending lipintegrally formed with the top end of the side wall, and (vii) adownwardly extending lip integrally formed with the side wall andextending below the bottom wall; (b) at a point during the shrinking ofthe molded plastic foam conical body: (i) positioning the cup in anupside down position such that the top end of the cup resides below thebottom end of the cup; (ii) positioning a reinforcing member at an acuteangle relative to a vertical plane and corresponding with an angle ofthe side wall of the cup, said reinforcing member having: (1) aconcavely shaped top edge, wherein a length of the concavely shaped topedge is less than the first length of the first diameter of the top endof the plastic foam cup, (2) a convexly shaped bottom edge, wherein alength of the convexly shaped bottom edge is less than the second lengthof the second diameter of the bottom end of the plastic foam cup, (3) acentral axis which runs through a center point of both the concavelyshaped top edge and the convexly shaped bottom edge of the reinforcingmember, (4) said center point defined by a trough of the concavelyshaped top edge and an apex of the convexly shaped bottom edge, (5) aninner surface, (6) an outer surface, and (7) a pressure sensitiveadhesive layer which covers substantially the entire inner surface;(iii) moving the cup and the reinforcing member toward an attachmentposition; (iv) at the attachment position, attaching the reinforcingmember to the side wall of the cup along or substantially along saidcentral vertical axis, wherein the top edge of the reinforcing member issubstantially aligned with the bottom end of the cup, the bottom edge ofthe reinforcing member is substantially aligned with the top end of thecup and the reinforcing member engages the side wall at the angle whichcorresponds with the angle of the side wall of the plastic foam cup; (v)rotating the cup and attached reinforcing member in a first direction toattach a trailing portion of the reinforcing member to the side wall ofthe cup, wherein said trailing portion includes an area of thereinforcing member from the central vertical axis to a trailing edge ofthe reinforcing member; (vi) rotating the cup and attached reinforcingmember in second opposite direction to attach a leading portion of thereinforcing member to the side wall of the cup, wherein said leadingportion includes an area of the reinforcing member from the centralvertical axis to a leading edge of the reinforcing member and theleading edge of the reinforcing member and the trailing edge of thereinforcing member define a first gap having a first gap width; and (c)allowing the molded plastic foam cup to further shrink, wherein afterthe molded plastic foam cup has further shrunk, the leading edge andtrailing edge of the attached reinforcing member define a second gaphaving a second gap width, the second gap width being less than thefirst gap width.
 7. The method of manufacturing a plastic foam cup ofclaim 6, wherein the first direction is counter clockwise and saidsecond direction is clockwise.
 8. The method of manufacturing a plasticfoam cup of claim 6, wherein the reinforcing member includes at leastone adhesive release edge.
 9. The method of manufacturing a plastic foamcup of claim 6, wherein the reinforcing member includes a vertically orsubstantially vertically extending sensing edge, said leading edge andsensing edge extending between the concavely shaped edge and convexlyshaped edge at one end of the material layer.
 10. The method ofmanufacturing a plastic foam cup of claim 6, which includes providingthe reinforcing member from a supply roll.
 11. The method ofmanufacturing a plastic foam cup of claim 6, which includes providingthe cup from a stack of cups.
 12. A method of reinforcing a plastic foamcup, said method comprising: (a) molding a plastic foam conical bodywhich has: (i) an open top end including an outwardly rolled lip, theopen top end having a first diameter of a first length, (ii) a closedbottom end having a second diameter of a second length, wherein thelength of the second diameter is less than the length of the firstdiameter, and (iii) a tapered wall extending from the bottom end to thetop end, said tapered wall having an outer surface and an inner surface;(b) providing a flat reinforcing member having: (i) a rigid materiallayer having an inner surface and an outer surface, (ii) a pressuresensitive adhesive layer which covers substantially the entire innersurface of the material layer, (iii) a concave edge, (iv) a convex edge,wherein a trough of the concave edge is aligned in a same plane as anapex of the convex edge, (v) a leading edge; (vi) a sensing edge, saidleading edge and sensing edge extending between the concave and convexedges at one end of the material layer, (vii) a trailing edge, saidleading edge and trailing edge extending in intersecting planes, whereina length between the leading edge and the trailing edge adjacent to theconcave edge is less than the first length of the first diameter of theopen top end of the plastic foam conical body and a length between theleading edge and the trailing edge adjacent to the convex edge is lessthan the second length of the second diameter of the closed bottom endof the plastic foam conical body, and (viii) an adhesive relief edge,said trailing edge and adhesive relief edge extending between theconcave and convex edges at an opposite end of the material layer, saidsensing edge and adhesive relief edge extending in substantiallyparallel planes (c) at a point during the shrinking of the moldedplastic foam conical body, affixing the outer surface of the flatreinforcing member around the tapered wall of the plastic foam conicalbody such that: (i) the concave edge is adjacent to the closed bottomend of the plastic foam conical body, (ii) the convex edge is adjacentto the open top end of the plastic foam conical body, (iii) the leadingedge and trailing edge extend in substantially parallel planes, (iv) thesensing edge and adhesive relief edge extend in intersecting planes; and(iv) the leading edge and trailing edge define a first gap having afirst gap width; and (d) allowing the molded plastic foam conical bodyto further shrink, wherein after the molded plastic foam conical bodyhas further shrunk, the leading edge and trailing edge of the affixedreinforcing member define a second gap having a second gap width, thesecond gap width being less than the first gap width.
 13. The method ofreinforcing a plastic foam cup of claim 12, which includes graphics onthe reinforcing member.
 14. The method of reinforcing a plastic foam cupof claim 12, which includes graphics printed on the outer surface of therigid material layer.
 15. The method of reinforcing a plastic foam cupof claim 12, wherein at a point during the shrinking of the moldedplastic foam conical body, the sensing edge and adhesive relief edge ofthe affixed reinforcing member define a third gap having a third gapwidth.
 16. The method of reinforcing a plastic foam cup of claim 15,wherein after the molded plastic foam conical body has further shrunk,the sensing edge and adhesive relief edge of the affixed reinforcingmember define a fourth gap having a fourth gap width, the fourth gapwidth being less than the third gap width.
 17. A method of reinforcing aplastic foam cup, said method comprising: (a) molding a plastic foamconical body during a first time period, wherein the plastic foamconical body has: (i) an open top end including an outwardly rolled lip,the open top end having a first diameter of a first length, (ii) aclosed bottom end having a second diameter of a second length, whereinthe length of the second diameter is less than the length of the firstdiameter, and (iii) a tapered wall extending from the bottom end to thetop end, said tapered wall having an outer surface and an inner surface;(b) providing a flat reinforcing member having: (i) a rigid materiallayer having an inner surface and an outer surface, (ii) a pressuresensitive adhesive layer which covers substantially the entire innersurface of the material layer, (iii) a concave edge, (iv) a convex edge,wherein a trough of the concave edge is aligned in a same plane as anapex of the convex edge, (v) a leading edge; and (vi) a trailing edge,said leading edge and trailing edge extending in intersecting planes,wherein a length between the leading edge and the trailing edge adjacentto the concave edge is less than the first length of the first diameterof the open top end of the plastic foam conical body and a lengthbetween the leading edge and the trailing edge adjacent to the convexedge is less than the second length of the second diameter of the closedbottom end of the plastic foam conical body, (c) affixing the outersurface of the flat reinforcing member around the tapered wall of themolded plastic foam conical body during the first time period such that:(i) the concave edge is adjacent to the closed bottom end of the plasticfoam conical body, (ii) the convex edge is adjacent to the open top endof the plastic foam conical body, (iii) the leading edge and trailingedge extend in substantially parallel planes, and (iv) the leading edgeand trailing edge define a first gap having a first width, and (d)storing the reinforced plastic foam cup for a second time period,wherein after the second time period, the leading edge and trailing edgeof the affixed reinforcing member define a second gap having a secondwidth, the second gap width being less than the first gap width.
 18. Themethod of reinforcing a plastic foam cup of claim 17, wherein theplastic foam conical body has a first size during the first time periodand a second size during the second time period, wherein the second sizeis smaller than the first size.
 19. The method of reinforcing a plasticfoam cup of claim 17, which includes graphics on the reinforcing member.20. The method of reinforcing a plastic foam cup of claim 17, whichincludes graphics printed on the outer surface of the rigid materiallayer.
 21. The method of reinforcing a plastic foam cup of claim 17,wherein prior to being affixed around the tapered wall of the plasticfoam conical body, the flat reinforcing member includes a sensing edgeand an adhesive relief edge, said leading edge and sensing edgeextending between the concave and convex edges at one end of thematerial layer, said trailing edge and adhesive relief edge extendingbetween the concave and convex edges at an opposite end of the materiallayer, and said sensing edge and adhesive relief edge extending insubstantially parallel planes.
 22. The method of reinforcing a plasticfoam cup of claim 21, wherein after affixing the outer surface of theflat reinforcing member around the tapered wall of the plastic foamconical body, the sensing edge and adhesive relief edge extend inintersecting planes.